position for a machine part or a piece of work, or 2 certain rotating speed. These devices take the place of a human operator and are often used un- der conditions where it would be impossible or impractical for the operator to be present or to ef- ciently direct the machine. Limit switches are used most frequently as overtravel stops for machines, equipment, and products in process. These devices are used in the control circuits of magnetic starters to govern the Starting, stopping, or reversal of electric motors. Electrical or Mechanical Interlock and Sequence Control Many of the electrical control devices de- scribed in this unit can be connected in an inter- locking system so that the final operation of one ‘er more motors depends upon the electrical posi- ‘ton of each individual control device. For exam- ple, a float switch may call for more liquid but will ot be satisfied until the prior approval of a pres- sure switch or time clock is obtained. To design, install, and maintain electrical controls in any elec ‘ical or mechanical interlocking system, the elec- ‘trical technician must understand the total opera- Sonal system and the function of the individual components. With practice, it is possible to trans- fer knowledge of circuits and descriptions for an understanding of additional similar controls. It is ‘mpossible—in instructional materials—to show all possible combinations of an interlocking con- trol system. However, by understanding the basic fonctions of control components and their basic ieuitry, and by taking the time to trace and draw Sircuit diagrams, difficult interlocking control sys- tems can become easier to understand. STARTING AND STOPPING In starting and stopping a motor and its as- sociated machinery, there are a number of condi- tions that may affect the motor. A few of them are discussed here. Frequency of Starting and Stopping The starting duty cycle of a controller is an important factor in determining how satisfactorily the controller will perform in a particular applica- tion. Magnetic switches, such as motor starters, relays, and contactors, actually beat themselves apart from repeated opening and closing thou- sands of times. An experienced electrician soon learns to look for this type of component failure when trouble shooting any inoperative control panels. NEMA standards require that the starter size be derated if the frequency of start-stop, jog- ging, or plugging is more than 5 times per minute. ‘Therefore, when the frequency of starting the con- troller is great, the use of heavy duty controllers and accessories should be considered. For stan- dard duty controllers, more frequent inspection and maintenance schedules should be followed, Light or Heavy Duty Starting Some motors may be started with no loads and others must be started with heavy loads. When motors are started, large feeder line distur- bances may be created which can affect the elec- trical distribution system of the entire industrial plant. The disturbances may even affect the power company’s system. As a result, the power compa- nies and electrical inspection agencies place certain limitations on “across-the-line” motor starting. Fast or Slow Start (Hard or Soft) To obtain the maximum twisting effort (torque) of the rotor of an ac motor, the best start- ing condition is to apply full voltage to the motor terminals. The driven machinery, however, may be damaged by the sudden surge of motion. To prevent this type of damage to machines, equip- ment, and processed materials, some controllers are designed to start slowly and then increase the motor speed gradually in definite steps. This type is often used by power companies and inspection agencies to avoid electrical line surges. UNIT 1 GENERAL PRINCIPLES OF ELECTRIC MOTOR CONTROL 9