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CableMatters Reliable Connectivity

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Ultimate Electrical Engineer’s Guide

Electric Motor Drives & Machines: Dynamics and Control

Fundamentals of Electric Motors and Electric Drives


above: Example of typical AC 3-phase induction motor (Courtesy Baldor Electric).

Industrial Electricians Standard Guide of Electricity

Basics of Industrial Electronics Troubleshooting

AC motors & starters (part 1) , more...

One of the keys to maximizing life in electric motors is to learn from one's premature failures. Use the Internet to research issues. Ask questions on topical forums. Partner with a service shop and learn from the types of failures they see and document. Then, take actions to prevent these failures from happening to your other motors in similar applications. This might involve changing your maintenance procedures. Perhaps you need to grease more or less, or use a more compatible grease. Perhaps you need to identify voltage supply problems (for instance, if you have bearing fluting from an adjustable speed drive). 2nd, check to see if contamination and water are getting into the motors. If either one of these is an issue, do you have the right enclosure? Does the enclosure need a higher level of environmental protection? If so, look into severe duty, IEEE 841 or washdown motors. Finally, if you want to maximize service life, empower the plant maintenance and purchasing folks to buy better motors that will last longer and reduce energy consumption for years. Buying the lowest-cost item doesn’t always equate to the lowest life cost. Studies show that a motor’s purchase price is only 2 percent of its total life-cycle cost.
above: Various motors by Baldor Electric Corp.

Basics of Variable-Speed Drives (VSD) and Power Electronics


above: AC motor inverter, VSD. (Courtesy Baldor.)


above: Reliance Electric's GV3000 Drives -- avail. in two styles to suit various apps.

Electric Machinery, Motor Drives and Electricity Power Systems


above: AC motor inverter, VSD. (Made by Hitachi)


above: Dayton Adjustable Frequency AC Drive - 1KBT7.

The modular range of 8200 vector frequency inverters in the power range from 0.25 to 90 kW provides a complete and consistent solution with everything you may need to facilitate operation, handling, diagnostics and communication. Pluggable function modules can be used to integrate the 8200 vector into the control and automation world of your machine or plant. The compact dimensions save you space in the control cabinet.
above: "Vector" series drives by Lenze.

Electronics students ... we have just set up this ...

Electric Machines & Transformers

In regard to proper lubrication, bearings must receive not only a good, quality lubricant but the correct quantity at the proper intervals in order to obtain optimum life and reliability. Under- or over-greasing can be detrimental to reliability. Under-greasing does not provide the lubricant at the time it is needed, resulting in bearing wear or heat damage. Over-greasing can damage shields or significantly increase operating temperatures due to fluid shear friction. This reduces the grease’s lubricating capability. Oil-lubricated bearings must have the correct type and viscosity of oil for the same reasons stated previously. Closely follow manufacturer’s recommendations for lubrication types, amounts and schedules. In regard to temperature, this is the nemesis of electric motors. Overload, under-voltage, over-voltage, unbalanced voltage and improper ventilation can all work to increase the motor’s operating temperature. The overused rule of thumb is that motor life is cut in half for every increase of 10 degrees Celsius. Although the rule’s accuracy may be in question, it illustrates the point well. Any care given to mitigate the operating temperature will be rewarded with increased life and reliability. And, don’t make the mistake of increasing the rated capacity of a motor applied in a high ambient temperature environment to accommodate the winding temperature increase. Particularly on enclosed machines, this could result in unacceptable bearing operating temperatures, leading to early demise.
above: Cutaway model motor from Emerson Corp. They advise: To maximize motor life, focus on proper lubrication and temperature.


above: Question: What are these devices? Answer: Electric motor electromagnetic brakes (made by Germany's INTORQ)


above: ...and these are electromagnetic clutches--also by INTORQ.


above: Clutch-brake combinations. By INTORQ.

Laboratory Manual for Electronics:


Switching Power Supply Guide:

Industrial Motor Control & Engineering Manual

Guide to Industrial Electric Motor Control

Lightweight Electric/Hybrid Vehicle Design: Current EV design approaches; Electric motor and drive-controller design

Inverters for Wind Power

Inverters for Photovoltaic Systems

Guide to Remote Control and Automation Techniques (industrial-electronics.com) -- Electric Motors & Solenoids

Guide to Small Electric Motors: Motor Testing -- SPEED-TORQUE CURVE (inaugural article)

Ultimate Guide to Electric Motors & Drives

Guide to Motors and Generators:
DC Machine Construction (inaugural article). More articles coming soon.

All About Lasers (With DIY Projects)

Service Technician's and Engineer's Guide to Electricity for Refrigeration, Heating + Air Conditioning

... and ...

Student's and Professional's Guide to Power Generation & Delivery:

What it's...

Our new guide introduces the concepts of power generation & distribution. The material is broken down into short segments which concentrate on specific concepts or applications of particular types of equipment. The detailed explanations are written in easy-to-understand language & concisely presents the needed knowledge. There are many illustrations & photographs which help to provide technical understanding & provide real-world reference. This type of explanation & application better prepares the learner to perform effectively on the job in installation, troubleshooting, repair, & service of electrical power generation & delivery.

The knowledge obtained in this guide permits the learner to progress further in the study of electrical systems. It should be understood that the study of electricity & the application of electrical products are continually changing. The electrical industry constantly introduces new & improved devices & material which in turn lead to changes in installation & operation of equipment. Electrical codes also change to reflect the industry needs. It is it essential that the learner continues to learn & update their knowledge of the current procedures & practices.

The text is easy to read & the units have been grouped by general subject. There are summaries of each unit which provide an opportunity to restate the most important topics of the unit. There are summaries of the units provided to summarize topic groups.

CableMatters Reliable Connectivity

Each unit begins with the learning objectives. An Achievement-Review Quiz at the end of each unit provides an opportunity for the learner to check their understanding of the material in small increments before proceeding. Some of problems presented in the guide require the use of simple algebra & the learner should be familiar with the math before trying to solve the equations . It is also essential that the reader have a basic understanding of the fundamentals of electrical circuits & basic electrical concepts.

It is recommended that the most recent edition of the National Electrical Code (published by the National Fire Protection Association) be available for reference & use as the learner uses this guide. Application state & local codes & regulations should also be consulted when making the actual installations.

  1. Operating Principles of DC Generators
  2. The Separately-Excited DC Generator
  3. The Self Excited Shunt Generator
  4. Compound wound DC generator
  5. Summary of Units 1-4
  6. Single Phase AC Generation Principles
  7. Introduction to Polyphase Circuits
  8. The Three-Phase Wye Connection
  9. The Three-Phase Delta Connection
  10. Summary of Units 6-9
  11. THREE-PHASE ALTERNATORS: Physical & Electrical Characteristics of Three-Phase Alternators
  12. Engine-Driven Generating Sets
  13. Parallel Operation of Three-Phase Alternators
  14. Wiring for Alternators
  15. Summary of Units 11-14
  16. TRANSFORMERS: Basic Principles of Industrial Transformers
  17. Single-Phase Transformers
  18. The Single-Phase, Three-Wire Secondary System
  19. Single-Phase Transformers Connected In Delta
  20. Single-Phase Transformers Connected in a Wye Installation
  21. Wye & Delta Connections of Single-Phase Transformers
  22. Instrument Transformers
  23. Three-Phase Transformers
  24. National Electrical Code Requirements for Transformer Installations
  25. Summary of Power Transformers Units 16-24
  26. Glossary of Power Generation & Delivery Terms

Student's & Professional's Guide to AC/DC Motors, Controls, & Maintenance:

  1. The DC Shunt Motor
  2. The DC Series Motor
  3. DC Compound Motors
  4. Summary of Units 1-3
  5. Manual Starting Rheostats for DC Motors
  6. Special DC Starting Rheostats & Controllers
  7. Basic Principles of Automatic Motor Control
  8. The DC Counter EMF Motor Controller & DC Variable Speed Motor Drives
  9. The DC Voltage Drop Acceleration Controller
  10. The DC Series Lockout Relay Acceleration Controller
  11. Dynamic Breaking With a DC Motor Reversal Control
  12. Summary Review of Units 5-11
  13. Electro-Mechanical & Solid State Relays & Timers
  14. Three-Phase, Squirrel Cage Induction Motor
  15. Starting Three-Phase, Squirrel-Cage Induction Motors
  16. Controllers for Three-Phase Motors
  17. Three-Phase Wound-Rotor Induction Motor
  18. Manual Speed Controllers For Wound-Rotor Induction Motors
  19. Summary for Units 13-18
  20. The Synchronous Motor
  21. Three-Phase Motor Installations
  22. Single-Phase Induction Motors
  23. Repulsion Motors
  24. Alternating Current Series Motors
  25. Selsyn Units
  26. Motor Maintenance
  27. Summary of Units 20-26
  28. Glossary

Student's & Professional's Guide to Industrial Electrical Devices, Circuits & Materials:

1.-10. (coming soon!)

11. Single-Phase, Three-Wire Service Entrance

12. Installation of a Single-Phase, Three-Wire Service Entrance for an Apartment Building

13. Installation of a Three-Phase, Three-Wire Service Entrance

14. (coming soon!)

15. (coming soon!)

Coming soon: Achieve maximum energy efficiency in electric motors! We delve in to technical, meaty topics in order to help you obtain (and, henceforth, expect) maximum efficiency from your AC drive, DC drive, stepper motor, generator, alternator ... & even motors suitable for electric & hybrid cars.

AC Drives & High-power Converters: Intro, Requirements, Motor-Side Challenges, Switching Device Constraints, Converter Configurations, MV Industrial Drives

University Physics

Direct-Current Motor

Articles list:

Articles-by-category section

 C- Face, 3 Phase. ODP Motor
Industrial Motors + Generators -- best price





3-phase Motor for General Purpose, Hazardous Location








Do You Know Your Motor Drive?

ABB ACS800 industrial AC inverter drives with direct torque control (DTC) as standard are available both as complete AC drives and as modules to meet the requirements of the users, OEMs and system integrators. The ACS800 range of ac inverters are highly flexible and can be configured to meet the precise needs of industrial applications, and hence order-based configuration is an integral part of the offering.
above: ABB Industrial Drive -- ACS800. They are complete AC variable speed drives, which can be installed without any additional cabinet or enclosure and used in process industries such as pulp & paper, metals, mining, cement, power, chemical, and oil & gas.



above: Motor Soft Starters by ABB. A less-cost alternative to VSDs.


above: Reliance Electric MD60 AC motor drive.


above: An extremely simple AC drive: DC2 Drive by Reliance Electric. Depending on your app. or budget, this may be all you need.

Key Attributes: Sensorless Vector Control (SVC); Operator Interface; Multi-line Graphic LCD Display; Icon Menu; Scalable Monitor Display; Control Modes; V/Hz. Sensorless Vector; Fan/Pump V/Hz.; Internal PI regulator; Flow control; Pressure control; Position control; Auto Tuning.
above: Reliance Electric's SP600 NEMA 4X/12. Washdown & Dust-Tight. Prices depend on HP, starting around $1500.00 for 0.5HP, up to $4800.00 for 20HP.
Know a starter from a relay from a contactor from a contactor? With so many choices these days, and with technologies merging, the differences seem confusing. Try to guess what each of these may be. For the answer, cursor over each of these images... Coupling Relays

Soft start

Contactor Relays

Motor Starter, Siemens

Electromechanic Motor Starter; Electronic Motor Starters with Integrated Soft Starter Function

Motor Starter: This Siemens isolator module with its switch disconnector function serves to safely isolate the 400 V operating voltage when repair work is being carried out in the plant. It features an integrated group-fusing function, i.e. additional group short-circuit protection for all series-connected motor starters. Depending on their power distribution concept, all stations can be optionally fitted with an isolator module.

Siemens SIRIUS Relays--functional block diagram

Timing Relays--Electronic timing relays are employed for all time-delayed switching processes in control, starting, protection and regulation circuits.



Coming soon: our comprehensive industrial robotics guide...

ABB robot









Motor-Gearbox: Preventive Maintenance (Lubrication) and Repair -- What to Look for in Products and Service Providers

Lubrication Management
  • Manual & Automated Grease & Oil Centralized Lubrication Systems
  • Lubrication System Components
  • Over The Road Truck & Heavy Mobile Equipment Systems
  • Complete Lube Equipment Testing & Repair Services
  • Factory-Trained Lubrication Equipment Warranty & Repair Service Center

Gearbox Repair Services
  • Complete Gearbox Repair & Overhaul
  • Inspect & Troubleshoot
  • Bearing & Seal Replacement
  • Custom/Obsolete Gearing
  • Vibration Analysis
  • Shaft Accessory Removal & Replacement
  • Eco-friendly Waste Oil Disposal
  • Factory-Authorized Build Center
  • Custom Ratios & Ratings
  • High-Efficiency Drives
  • Quick Turn Around
  • Stocked Sub-Assemblies & Components
  • Oil & Wear Particle

Essential Books for Industrial Electronics — Topics include AC/DC drives, motor controls, PLC, troubleshooting & more. Books target those interested in: Trades, Journeymen, Engineering textbooks, & more.

Recommended Books:

National Electrical Code 2005 Softcover VersionNational Electrical Code 2005 Softcover Version

The single most important reference in the electrical industry, the National Electrical Code (NEC), is updated every three years & outlines minimum standards for all types of electrical installations. The 2005 NEC, available in softcover or looseleaf version, is loaded with solutions designed to provide better safeguards, add greater usability, & bring provisions in line with technology trends. A must for anyone involved in electrical design, installation, or inspection, the 2005 NEC® provides 100% of the information needed to meet Code® & avoid costly errors in electrical installations of all types. Thomson Delmar Learning is pleased to make this authoritative reference from the NFPA available directly from us, for the convenience of our customers who work in & around the electrical trades. It may be used independently or as a companion to any electrical book, including Delmar's best-selling wiring series as well as our guides to using the NEC®.

Every three years the National Electrical Cod2 is significantly revised to keep pace with technology & enhance protection against electrical fire & shock hazards. Get in position to advance your knowledge & be prepared with the newest codes. The 2005 National Electrical Code is loaded with solutions designed to provide better safeguards, add greater usability, & bring provisions in-line with technology trends. It's a "must" for anyone who works with electric conductors or equipment. Revisions include: Expanded AFCI protection in wiring systems New rules for GFCI protection Identification of ungrounded branch circuit & feeder conductors All-new articles for control panels & speed-drive systems Reorganized rules in Article 220: Branch Circuit, Feeder & Service Calculations New zone hazardous area classification system for combustible dusts & ignitable fibers & flyings. You'll help improve electrical safety for millions of people with the latest edition of the NEC; the world's most widely adopted safety code.

Review:

Required reference for handymen & professional electricians: "The National Electric Code, also knows as NFPA-70, is the standard that building officials use to define what is legal to use in electric services of all kinds. NFPA is the National Fire Protection Association. The Electric Code began almost as soon as Edison wired some of his new lights in New York, & the first electricity caused fire happened. Soon thereafter the National Fire Protection Association began writing safety codes aimed at preventing fires & promoting safe wiring techniques. Today, more than a century later, the Electric Code is republished every 3 years. As new inventions & new applications for electricity are ever expanding the code book expands & is revised to define the new applications. The 2005 edition has been updated to include recent developments in available materials & equipment. The code has 772 large pages detailing every electric installation from common house wiring to installation requirements for 35,000 volt transformers. The tables detailing how many conductors you can put in a conduit go on for 50 pages in the appendix.

The problem most people have with the code comes from its complexity & scope. If you are a handyman, or even an electrician, it takes years of study to learn all its requirements, & even then they change it on you. It can be helpful though. One year I was installing wire for a welder in my garage. I found a paragraph that allowed me to derate the current load of the conductors based on the duty cycle percentage of the welder. I saved quite a bit of money on heavy wire that wasn't needed, & had a safe installation. The code is so long & complex that several other books have been written to help professional & amateur electricians understand the code, translating it's stilted language & detailed requirements into plain English for common applications. The "Illustrated Guide to the National Electric Code," by Charles R. Miller, is one of the better ones. There are also numerous how-to handbooks on electric wiring based on the code. E.g., "Wiring Simplified," by Richter & others. is an easy do-it-yourself guide. However, even an illustrated guide book isn't the code. When the electric inspector comes out to review your work you need to know that you wired it correctly. You can bet he's read the code & will be approving or disapproving your work based on its requirements.

Over the years I've had to repair & straighten out many half-baked & outright dangerous electric installations. Many of them were done by well meaning men who just didn't know how electric wiring was supposed to be done. I recommend that everyone doing wiring from homeowner to seasoned electrician, to electric engineer ought to own a current copy of the National Electric Code. The 2005 edition will be current until 2008."

Purchase National Electrical Code 2005 Softcover Version

Industrial Electronics: Applications for Programmable Controllers, Instrumentation Process Control, and Electrical Machines and Motor Controls (3rd Edition)Industrial Electronics: Applications for Programmable Controllers, Instrumentation & Process Control, & Electrical Machines & Motor Controls (3rd Edition)

by Thomas E. Kissell

Book Description:
Based on the author's experience working with technicians directly on the factory floor in major industries, this handbook/reference covers all of the electronic technology found in modern industrial systems, going into the depth required to install, troubleshoot, & repair complex automation systems. Each stand-alone (but cross-referenced) section explores either an entire system or individual circuits & components that are used over & over in a large variety of complex systems. Features a large number of figures, diagrams, & pictures, & typical Job Assignments, with solutions. Advanced Solid State Logic: Flip-Flops, Shift Registers, Counters & Timers. Programmable Controllers. Solid-State Devices Used to Control Power: SCRs, TRIACs & Power Transistors. Solid-State Devices Used for Firing Circuits. Photoelectronics, Lasers & Fiber Optics. Industrial Power Supplies, Inverters & Converters. Operational Amplifiers. Open-Loop & Closed-Loop Feedback Systems. Input Devices: Sensors, Transducers, & Transmitters for Measurement. Output Devices: Amplifiers, Valves, Relays, Variable-Frequency Drives, Stepper Motors & Servomotor Drives. AC & DC Motors & Generators, Transformers, & Three-Phase Electricity. Case Studies of Four Industrial Applications. Robots & Other Motion Control Systems. Motor-Control Devices & Circuits. Data Communications for Industrial Electronics. For Instrumentation & Process Control Technicians, PLC & Motion Control Technicians.

Purchase this book

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Hard-to-Find, Wholesale-Priced Computer Parts — heavily-discounted computer surplus for organizations, industry, government & consumers.

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