Electricity & Electronics For Industrial Maintenance

Electricity & Electronics For Industrial Maintenance

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This reference shows how industrial components and systems operate, how they are installed and maintained, and how to diagnose and service any malfunctions. Using a systems approach, this book provides the perfect blend of theory and application for today's technicians to understand how electrical, electronic control, and PLC parts interact to make complex modern industrial machines operate. This understanding aids troubleshooting of everything from simple circuits to complex PLC controlled systems with electronic variable frequency drives.
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Product details

  • Hardback | 336 pages
  • 208 x 272 x 18mm | 698.54g
  • Pearson
  • Upper Saddle River, NJ, United States
  • English
  • New.
  • 013117598X
  • 9780131175983

Table of contents

1. Shop Safety and Shop Practices.


Safety Glasses, Protective Clothing, and Equipment.

Safety Mats and Equipment to Prevent Fatigue.

Safety Light Curtains and Two-Hand Start Buttons.

Safety Gates and Shields.

Checking Guards and Active Safety Devices.

Cleanliness and Shop Housekeeping.



First Aid, CPR and Portable Defibrillators.

Fire Safety.

Electrical Safety.

Working Safely with Hand Tools and Power Tools.

Safety Briefings and Safety Meetings.

Safety Standards Organizations in the United States, Canada, and Europe.

2. Tools for Electrical Technicians.

Overview of Electrical Tools.

Electrical Meters.

Hole Punches and Hole-Cutting Tools.

Electrical Conduit Bending, Cutting, and Threading Tools.

Electrical Pliers, Wire Cutters, and Wire Strippers.

Screwdrivers for Electrical Installation and Maintenance.

Wrenches for Electrical Maintenance.

Tool Pouches and Tool Belts.

Proper Use of Tools.

3. Fundamentals of Electricity.

Overview of Electricity.

Example of a Simple Electrical Circuit.

Example of Voltage in a Circuit.

Example of Current in a Circuit.

Example of Resistance in a Circuit.

Identifying the Basic Parts of a Circuit.

Wiring Diagram and Ladder Diagram.

Equating Electricity to a Water System.

Using Ohm's Law to Calculate Volts, Amperes, and Ohms.

Ohm's Law Formulas.

Using Ohm's Law to Calculate Voltage.

Using Ohm's Law to Calculate Current.

Using Ohm's Law to Calculate Resistance.

Using the Ohm's Law Wheel to Remember the Ohm's Law Formulas.

Calculating Electrical Power.

Presenting All the Formulas.

Using Prefixes and Exponents with Numbers.

4. Voltmeters, Ammeters, and Ohmmeters.

Measuring Volts, Amps, and Ohms.

Measuring Voltage.

Measuring Electrical Current.

Measuring Milliamps.

Creating a Multiplier with a Clamp-on-Type Ammeter.

Measuring Electrical Resistance.

Reading the Scales of a VOM Meter.

Measuring DC Volts and Reading the VOM Scales.

Measuring and Reading the Milliamp Scales on the VOM.

Measuring and Reading Resistance Scales on the VOM.

Making Measurements with Digital VOM Meters.

5. Series Circuits.


Examples of Series Circuits.

Series Switches.

Adding Loads in Series.

Resistor Color Codes.

Decoding a Resistor.

Why Resistor Tolerance Is Important.

Variable Resistors.

Using Ohm's Law to Calculate Ohms, Volts, and Amps for Resistors in Series.

Solving for Current in a Series Circuit.

Calculating the Voltage Drop Across Each Resistor.

Calculating the Power Consumption of Each Resistor.

Calculating the Power Consumption of an Electrical Heating Element.

Troubleshooting Series Switches.

Review of Series Circuits.

6. Parallel and Series-Parallel Circuits.


Calculating Voltage, Current, and Resistance in a Parallel Circuit.

Calculating Resistance in a Parallel Circuit.

Calculating Power in a Parallel Circuit.

Reviewing the Principles of Parallel Circuits.

Review of Using Prefixes with Units of Measure.

Series-Parallel Circuits.

Series-Parallel Circuits in Factory Electrical Systems.

Review of Series-Parallel Circuits.

7. Magnetic Theory.

Introduction to Magnetic Theory.

A Typical Bar Magnet and Flux Lines.


Adding Coils of Wire to Increase the Strength of an Electromagnet.

Using a Core to Increase the Strength of the Magnetic Field of a Coil.

Reversing the Polarity of a Magnetic Field in an Electromagnet.

Electromagnetic Theory Used to Operate a Basic Generator to Create AC Voltage.

Magnetics Used in Basic Theory of a Simple DC Motor.

Electromagnetic Induction Used in Transformers.

Magnetics Used in Relays and Contactors.

Review of Magnetic Principles.

8. Fundamentals of AC Electricity.

What Is Alternating Current?

Where Does AC Voltage Come From?

Frequency of AC Voltage.

Peak Voltage and RMS Voltage.


The Source of AC Voltage for Factory Electrical Systems.

Measuring AC Voltage in a Disconnect.

Voltage and Current in AC Circuits.


Resistance and Capacitance in an AC Circuit.

Calculating Capacitive Reactance.

Calculating the Total Opposition for a Capacitive and Resistive Circuit.

Resistance and Inductance in an AC Circuit.

Calculating Inductive Reactance.

Calculating the Total Opposition for and Inductive and Resistive Circuit.

True Power and Apparent Power in an AC Circuit.

Calculating the Power Factor.

9. Transformers and Three-Phase and Single-Phase Voltage.

Overview of Transformers.

Operation of a Transformer and Basic Magnetic Theory.

Connecting a Transformer to a Disconnect for Testing.

Transformer Rated for 240V and 208V Primary.

Transformer Voltage, Current, and Turns Ratios.

Step-up and Step-down Transformers.

VA Ratings for Transformers.

The 120-VAC Control Transformer.

Wiring the Control Transformer for 480-VAC Primary Volts.

Wiring the Control Transformer for 240-VAC Primary Volts.

Troubleshooting a Transformer.

Nature of Three-Phase Voltage.

Why Three-Phase Voltage is Generated.

Three-Phase Transformers.

The Wye-Connected Three-Phase Transformer.

The Delta-Connected Three-Phase Transformer.

Delta- and Wye-Connected Transformers with a Neutral Terminal.

The High Leg Delta System.

Three-Phase Voltage on Site.

Installing Wiring in a Three-Phase Disconnect.

Testing for a Bad Fuse in a Disconnect.

Single-Phase Voltage from a Three-Phase Supply.

Bus Duct and Bus Disconnect Boxes.

Wiring a Duplex Receptacle as a Utility Outlet.

10. Relays, Contactors, and Solenoids.

Overview of Relays and Contactors in the Control Circuit.

The Control Transformer.

The Theory and Operation of a Relay.

Types of Armature Assemblies for Relays.

Pull-in and Hold-in Current.

Normally Open and Normally Closed Contacts.

Ratings for Relay Contacts and Relay Coils.

Identifying Relays by the Arrangement of Their Contacts.

Examples of Relays Used in Industrial Electrical Systems.

Current Relays and Potential Relays for Starting Single-Phase Compressors.

The Difference between a Relay and a Contactor.

NEMA Ratings for Contactors.

The Function of the Control Circuit.

Solenoids Used in Industrial Systems.

Basic Parts of a Solenoid Valve.

Troubleshooting a Solenoid Valve.

11. Motor Starters and Over-Current Controls.

Overview of Motor Starters.

Why Motor Starters Are Used in Industrial Electrical Systems.

The Basic Parts of a Motor Starter.

The Operation of the Overload.

Exploded View of a Motor Starter.

Sizing Motor Starters.

Solid-State Motor Protectors.

Over-Current Controls.

Thermal Overloads.


Fused Disconnect Panels.

Circuit Breakers and Load Centers.

12. Motor-Control Devices and Circuits.


Pilot Devices.

Control Circuits and Load Circuits.

Jogging Control Circuits.

Other Types of Pilot Devices.



13. Single-Phase AC Motors.

Overview of Single-Phase AC Induction Motors.

AC Split-Phase Motor Theory.

The Rotor.

Locked-Rotor Amperage and Full-Load Amperage.

Rotor Slip and Torque in an AC Induction Motor.

End Plates.

The Stator.

The Start Winding.

The Operation of the Centrifugal Switch.

The Run Winding.

Multiple-Speed Motors.

Motor Data Plates.

Wiring Split-Phase Motors for a Change of Rotation and Change of Voltage.

Overview of Capacitor-Start, Induction-Run Motors.

Theory of Operation for a Capacitor-Start, Induction-Run Motor.

Applying Voltage to the Start Winding and Capacitor.

Wiring Split-Phase and Capacitor-Start, Induction-Run Motors for 115V.

Wiring a Capacitor-Start, Induction-Run Motor for 230V.

Wiring a Split-Phase and Capacitor-Start, Induction-Run Motor for a Change of Rotation.

Changing Speeds with a Capacitor-Start, Induction-Run Motor.

Overview of Permanent Split-Capacitor Motors.

Basic Parts and Theory of Operation for a PSC Motor.

Applying Voltage to the Start Winding and Capacitor of a PSC Motor.

14. Three-Phase Motors.

Three-Phase Motor Theory.

Basic Parts of a Three-Phase Motor.

Theory of Operation for a Three-Phase Motor.

Wiring a Simple Three-Phase Motor.

Changing Connections in Three-Phase Motors to Change Torque, Speed, or Voltage Requirements.

Wiring a Three-Phase Motor in a Wye Configuration.

Wiring a Three-Phase Motor in a Delta Configuration.

Rewiring a Nine-Lead, Three-Phase, Wye-Connected Motor for a Change of Voltage.

Rewiring a Nine-Lead, Three-Phase, Delta-Connected Motor for a Change of Voltage.

The 12-Lead, Three-Phase Motor.

Wiring a Three-Phase Motor for a Change of Rotation.

Controlling a Three-Phase Motor.

Controlling the Speed of a Three-Phase Motor.

Troubleshooting the Three-Phase Motor.

Testing the Three-Phase Motor for Continuity.

Testing a Three-Phase Motor for Current.

15. DC Motors.


Magnetic Theory.

DC Motor Theory.

DC Motor Components.

DC Motor Operation.

Types of DC Motors.

DC Shunt Motors.

DC Compound Motors.

16. DC Generators.


Basic Parts and Basic Operation of a DC Shunt Generator.

Separately Excited Shunt Generator.

Self-Excited Shunt Generator.

Compound Generator.

Series Generator.

Controlling the Amount of Voltage and Its Polarity in a DC Generator.

Troubleshooting a DC Generator.

17. AC Alternators.


Theory of Operation of the Alternator.

AC Voltage in the Stator.

Producing Three-Phase Voltage.

Using an Alternator to Produce DC Voltage.

Troubleshooting an Alternator.

18. Programmable Controllers.


The Generic Programmable Logic Controller.

Understanding How the PLC Controls a Simple Circuit with a Selector Switch and Motor-Starter Coil.

Using Change of State and Power Flow to Understand the Stop-Start Circuit.

The PLC Program for the Stop-Start Circuit.

An Example Programmable Controller Application.

The Run Mode and the Program Mode.

On-line and Off-line Programming.

Features of the Programmable Controller.

Classifications of Programmable Controllers.

Review the Operation of Programmable Controllers.

Addresses for Inputs and Outputs for the MicroLogix PLC.

Example Input and Output Instructions for the MicroLogix.

More about Mnemonics: Abbreviations for Instructions.

Example of a Program with Inputs Connected in Series.

Using Timers in a PLC.

Counter Applications for Industry.

Entering Programs with the Hand-Held Programmer.

Programming Basic Circuits into the PLC.

Wiring a Stop-Start Circuit to Input and Output Terminals on the PLC.

Typical Problems a Technician Will Encounter with PLCs.

Troubleshooting the PLC.

19. Electronics for Maintenance Personnel.

Overview of Electronics Used in Industrial Circuits.

Conductors, Insulators, and Semiconductors.

Combining Atoms.

Combining Arsenic and Silicon to Make N-Type Material.

Combining Aluminum and Silicon to Make P-Type Material.

The PN Junction.

Forward-Biasing the PN Junction.

Reverse-Biasing the PN Junction.

Using a Diode for Rectification.

Half-Wave and Full-Wave Rectifiers.

Three-Phase Rectifiers.

Testing Diodes.

Identifying Diode Terminals with an Ohmmeter.

Light-Emitting Diodes.

PNP and NPN Transistors.

Operation of a Transistor.

Typical Transistors.

Troubleshooting Transistors.

Unijunction Transistors.

Operation of the UJT.

Testing the UJT.

The Silicon-Controlled Rectifier.

Operation of a Silicon-Controlled Rectifier.

Controlling an SCR.

Testing an SCR.

Typical SCRs.


Operation of a Diac.


Using a Triac as a Switch.

Using a Triac for Variable Voltage Control.

Testing a Triac.

Operational Amplifiers.

The Op Amp as an Amplifier.

Controlling a Relay with an Op Amp.

Controlling the Speed of a Three-Phase Motor with a Variable-Frequency Drive.

Operation of the Variable-Frequency Drive Circuit.

Solid-State Relays.

20. Lockout, Tag-out.


A Typical Lockout, Tag-out Policy.

Determining the Lockout, Tag-out Policy and Procedure.

Identifying Sources of Kinetic Energy and Potential Energy.

Designing Safety into the Machine.

Documentation and Training.

OSHA Inspections.

What Is Lockout?

What Is Tag-Out?

Designing a Lockout, Tag-out Procedure for Your Machines.

Removing the Lockout, Tag-out Devices and Returning Power to the Machine.

Review of Lockout, Tag-out Procedures.

21. Troubleshooting.


What Is Troubleshooting?

The Difference between Symptoms and Problelms.

Starting the Troubleshooting Procedure.

Developing a Ladder Diagram from a Wiring Diagram.

Converting a Wiring Diagram from a Ladder Diagram.

Auto Mode and Manual Mode.

Review of Troubleshooting.


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