Industrial Control Wiring Guide - Weebly

1 Industrial ControlWiring GuideIndustrial ControlWiring GuideSecond editionBob MercerOXFORD AUCKLAND BOSTON JOHANNESBURG MELBOURNE NEW DELHIN ewnesAn imprint of Butterworth-HeinemannLinacre House, Jordan Hill, Oxford OX2 8DP225 Wildwood Avenue, Woburn, MA 01801-2041A division of Reed Educational and Professional Publishing member of the Reed Elsevier plc groupFirst published 1995 Reprinted 1996, 1998, 1999 Second edition 2001 R. B. Mercer 1995, 2001 All rights reserved.

2 No part of this publication may be reproduced inany material form (including photocopying or storing in any medium byelectronic means and whether or not transiently or incidentally to someother use of this publication) without the written permission of thecopyright holder except in accordance with the provisions of the Copyright,Designs and Patents Act 1988 or under the terms of a licence issued by theCopyright Licensing Agency Ltd, 90 Tottenham Court Road, London,England W1P 0LP.

3 Applications for the copyright holder s writtenpermission to reproduce any part of this publication should be addressedto the publishersBritish Library Cataloguing in Publication DataA catalogue record for this book is available from the British LibraryISBN 0 7506 3140 6 Composition by Genesis Typesetting, Laser Quay, Rochester, KentPrinted and bound in Great Britain1 Personal Building safe Types of Wire types and Insulation Wire Standard Wire Coaxial and screened Multiway Insulation Soldering and Soldering Forming the Soldering the Crimped Screw clamp Terminating coaxial Cable Continuous Spot Laying the Twisted Cable Connections and Conductor and cable Conductors of different Component mounting Plastic Connector Screw Components (active)

4 Contactors and Components (passive) Switches and Earthing and Earthing the protective Screen System earth PLC Power supply Wiring of inputs and Personal safetyConcern for your own safety as well as the safety of others should always be on your mind. Most safetyprocedures are common sense but, because some hazards are not obvious, there are regulations born outof experience which are designed to make the workplace are two aspects of safety which concern us in the assembly of electrical equipment and first concerns your own personal safety.

5 In the words of the Health and Safety Regulations: the need to use safe working practices and safety equipment to avoid the risk of injury to yourselfand to others in the course of your it is beyond the scope of this book to cover the detail of all the safety precautions and safe workingpractices which should be adopted, there are some general points which can be noted. Safety equipment, goggles, gloves, etc., should be provided and must be usedwhere they areappropriate.

6 The onus is on you to use the safety equipment provided by your company. Any damage to safetygear should be reported. Safe working practices are part of any job and you should always learn andadopt them as a natural way of working. Don t take shortcuts which compromise your safety, or that of anybody else. You should make yourself aware of the procedures used at your place of work to prevent accidentsand to deal with common incidents. You should know how to isolate electric supplies and how to work safely on electrical Accidents Know how to contact the correct person thedesignated first aider for help.

7 Find out the location of the nearest first aidbox. Know how to isolate electric supplies and howto release a person safely from contact FireBefore commencing work on electric plant, youshould know: Where is the nearest fire alarm activator, fire exitand fire extinguisher? Are the fire exits clear of equipment orrubbish? Extinguishers for electrical firesBe aware that special extinguishersare needed forfires which occur in live electrical equipment do notuse water-based extinguishers.

8 RED extinguishers are water-based for wood/paper/cloth/plastic fires only. GREEN extinguishers are halon or BCF-basedfor general fires (not gases) including electricalfires. BLACK extinguishers are CO2-based for flam-mable liquids and electrical Electric shockLearn the basic first aid action drill. DO NOT TOUCHthe victim with your barehands until the power is off or they have beenpulled away from contact otherwise you will geta shock as well. Switch off the power and drag the victim off thelive conductor.

9 Alternatively if you cannot switch off then usesomething non-conductingto move the victimaway from contact. Dry wood, plastic tubing(PVC conduit) even a dry piece of cloth foldedseveral times will Working with electrical equipmentMany of the tools we use are electrically powered,some by the mains, some by battery. Mains-driven portable tools should be connectedto the supply through an isolating transformer. These are usually 110 V systems which reducethe effect of electric shock.

10 Heavier, fixed machines are wired into the three-phase factory supply. This is 415 V and there arestringent safety regulations governing its installa-tion and .. Do not take liberties or chances with electricity. Don t interfere with electrical apparatus, use it as intended and don t remove any covers orpanels. Don t use or tamper with electrical machinery and tools that do not concern you. Leave switches andbuttons alone. If you want to know how something works then ask someone who is authorised toshow you.