Introduction to Industrial

Electronics

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 Prerequisites and Books
Title : EEE435 Industrial Electronics
Prerequisites: EEE374 Electrical Measurements and Instrumentation
EEE232 Electronics II

Text Book
 [1] Programmable Logic Controllers,” Third Edition, Author Frank D. Petruzella, 2005,
McGraw-Hill.
[2] Process Control Instrumentation Technology", Eighth Edition, Author Curtis
Johnson, 2005 Prentice Hall
Reference Books
[1] “Industrial Electronics,” Author Frank D. Petruzella, 2002, McGraw-Hill.
[2] “Industrial and Power Electronics,” Author G.K.Mithal, M.Gupta, Khanna Publishers
[3] “Modern Industrial Electronics,” Fourth Edition, Author Timothy J.Maloney, 2001,
Prentice Hall

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 Contents to cover
• Industrial wiring, Grounding, General Electrical safety Precautions,
• Electric heating: Principles and applications; induction and dielectric heating; high-
frequency heating, Electric Welding, Spot welding control.
• Ladder Diagrams, Wiring diagrams, Block Diagrams,
• Switches, Electromechanical control relays, Solid-state relays,
• Hydraulic and pneumatic Actuators, Sensors and transducers, Temperature &
humidity, Displacement, Magnetism, pressure, fluid flow & liquid level,
• Types of process control, controller Responses,
• Motion and temperature control, Time and sequence control,
• Control and derive mechanism for different types of Motors used in industry,
• Programmable Logic controllers, Programming in ladder diagrams & interfacing
PLCs, Distributed systems,
• Computer controlled Machines and Processes, Interfacing Machines with PC NC
and CNC.

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 Safety rules
Safe practices will protect you and your fellow workers
• Do not work when you are tired or taking medicine that makes you
drowsy.
• Do not work in poor light.
• Do not work with wet shoes and clothing.
• Use approved tools equipment and protective devices.
• Never assume that a circuit is off, it may have static charge like capacitor.
So, double check it with an instrument that you are sure is operational.
• Make sure that power will not be turned on while a technical person is
working on a circuit.
• Avoid wearing metallic rings, bracelets and similar items when working
with exposed circuits.

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 Safety rules (Continued…)
• Never temper with safety devices such as an interlock (a type of switch that
automatically removes power when a door is opened or panel removed).
• Do not remove grounds in any case.
• Use approved fire extinguisher for electric and electronic equipment. Water
can conduct electricity and may severely damage equipment. CO 2 and
halogenated type extinguisher are usually preferred.
• Take care of some materials used in electronic equipment are toxic. Like
tantalum capacitor and beryllium oxide transistor, other material like heat
shrink tubing may produce irritating fumes if overheated.
• Use protective clothing and safety glasses when handling high-vacuumed
devices such as picture tubes and cathode ray tubes.
• Don’t work on equipment before you know proper procedure and are aware
of any safety hazard. Go through the operational manuals of the equipment
first.
• Strictly avoid the running, horseplay and practical jokes at the industrial places
and laboratories. 5
 Lecture#1: Contents
• Electric Shocks
• Safety in the Workplace
• Grounding
• General Electrical safety precautions
• First aid
• Fire prevention
• Electrical codes and standards

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 Electric shock
• Shock hazard is inversely proportional to the body resistance.
• Shock intensity depends upon current amount and time duration it last.
• Pathway through body is also a criteria of damage.
• 5mA is considered dangerous

Skin Condition Resistance value in ohm

Dry skin 100K to 600K
Wet skin 1K
Internal body- hand to foot 400 – 600
Ear to ear 100
• .

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Effect of current

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 Effects of Electricity on the Human Body

• The four major types of electrical injuries are:

– Direct
• Electrocution
• Electrical Shock
• Burns
– Indirect
• Falls

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3rd degree Electrical burn

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Personal Protective Equipment PPE
• Hard hats, safety shoes and
goggles must be worn in areas
where they are specified
• Safety earmuffs in noisy area
• Clothing should fit snugly to
avoid near moving machinery.
• Metal jewelry should not be
worn on energized circuits.
• Long hair should be confined
or kept trimmed

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A. Electrical Hazards – What is Electricity?
1. Improper Grounding
2. Exposed Electrical Parts
3. Inadequate Wiring
4. Damaged Insulation
5. Overloaded Circuits
6. Damaged Tools & Equipment
7. Wet Conditions
8. Overhead Power Lines

B. Accident Prevention:
1. Personal Protective Equipment
2. Inspect Tools & Cords
3. AFCIs & GFCIs
4. Lock-Out/Tag-Out

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 Safety in Work Place
• OSHA (occupational safety and health administration)
• To secure the safety, health and welfare of person at work against
risks to safety or persons at work. To protect persons at a place of
work other than persons at work against risk
to safety of health arising out of the activities of persons at work.
• Obey all accident prevention sign and cautions.
Red: Danger
Orange: Warnings
Yellow: Cautions
Blue: Notices
Green: Safety first
Purple: Radiation hazards

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 Fire Prevention
It is very important part of any safety program
In case of an electrical fire the following procedure should be
followed.
• Trigger the nearest fire alarm.
• Disconnect electric power
• Use CO2 or dry powdered fire extinguisher to put out the fire.
• Ensure that all persons leave the danger area in an orderly
fashion
• Do not reenter the premises unless advised to do so by fire
department personnel.

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Fire Extinguisher types

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 Grounding

– Grounding is another method of protecting you from

electric shock.
– However, it is normally a secondary protective measure.

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 Electrical Hazard Protections
• Grounding refers to the deliberate connection of parts of a wiring installation
to a common earth connection.
• Ungrounded power tool can kill you.
• Grounding reduces the safety but does not eliminate the danger.
• Ground fault circuit interrupter (GFCI) a supplimentary protection

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 Electrical Hazard Protections
• Ground Fault Circuit Interrupters (GFCI)
– Detects the difference in current between two circuits wires.
– This difference in current could happen when electrical equipment isn’t
working correctly.
– GFCI are set at about 5mA and are designed to protect workers and not
equipment.

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 Electrical Hazard Protections
• An Arc Fault Circuit Interrupter (AFCI) is a type
of duplex receptacle or circuit breaker that
breaks the circuit when it detects a dangerous
electrical arc in order to prevent electrical
fires.

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 Difference
There is a major difference between the functioning of an AFCI as
compared to a GFCI (Ground Fault Circuit Interrupter).
• The function of the GFCI is to protect people from the deadly effects of
electric shock that could occur if parts of an electrical appliance or tool
become energized due to a ground fault.
• The function of the AFCI is to protect the branch circuit wiring from
dangerous arcing faults that could initiate an electrical fire.
• An AFCI is a product that is designed to detect a wide range of arcing
electrical faults to help reduce the electrical system from being an
ignition source of a fire. Conventional overcurrent protective devices do
not detect low level hazardous arcing currents that have the potential to
initiate electrical fires.
• Electrical fires can be a silent killer occurring in areas of the home that
are hidden from view and early detection
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 General Electrical safety
• Never take a shock on purpose
• Keep material or equipment away from high voltages.
• Avoid working on live circuit.
• Avoid touching grounded objects while working on electrical equipment
• Use good electrical practices even in temporary wiring for testing
• Discharge capacitor before handling them
• Never use Ohmmeter on a live circuit.
• Never connect an ammeter in parallel with voltage source
• Never overload an ammeter or voltmeter.
• Make sure that terminal you measuring across not accidently shorted.
• On-line troubleshooting is recommended only for control voltages.

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 First AID
First aid is the immediate and temporary care given to the
victim of an injury or illness. Its purpose is to preserve
life, assist recovery, and prevent aggravation of the
condition.
• Bleeding : to control apply direct pressure on the wound using clean pad
or hand, raise the affected area above heart level.
• Burn: for first degree and minor second degree immense in cold water or
apply cold pads. For second degree with open blisters and all third degree
do not apply water and cold pads. For serious burns get medical help asap.
• Electric shock: Do not touch the victim unless separated from the supply. If
not breathing begin artificial respiration. Keep the victim warm and lower his head.

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Artificial respiration procedure CPR
• Cardio Pulmonary Resuscitation
• CPR is an emergency procedure that combines chest
compression often with artificial ventilation in an effort to
manually preserve intact brain function until further measures
are taken to restore spontaneous blood circulation and
breathing in a person who is in cardiac arrest. It is indicated in
those who are unresponsive with no breathing or abnormal
breathing

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 Artificial respiration CPR
• Place the victim on his back immediately. Turn the head and
clear the throat area of water, mucus, foreign objects or food.
• Tilt the victims head back to open the air passage.
• Lift the victim’s jaw up to keep the tongue out of the air
passage
• Pinch the victim’s nostrils close to prevent air leakage when
you blow
• Seal your lips around the victim’s mouth
• Blow into the victim’s mouth until you see the chest rise
• Remove your mouth to allow natural exhalation.
• Repeat 12 to 18 times per minute, watch the victim’s chest
rises and falls until natural breathing starts
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 Electrical codes and standards
• Two of the institutions responsible for safety are the National Fire Protection
Association, which sponsored the National Electrical Codes (NEC) and the national
Board of Fire Underwriters, which created the Underwriter’s Laboratories.
• NEC is a set of guidelines describing procedures that minimize the hazards of
electric shock, fires and explosions caused by electrical installation. NEC gives
tabulation of safe current carrying capacities of various types and sizes of wire. This
is a practical source of information as it includes the limitation of various types of
insulation and effect of various applications. The NEC is reprinted every three years;
there are a number of changes each time a new edition is issued.
• The NEC is not a text book to be used as a basis of instruction. Rather, it is a set of
rules developed over many years; that has been found to provide safe and practical
electrical installations. “Shall” and “should” are frequently used in the NEC. “Shall”
pertains to the things that must be done to be accepted by the code; “should” are
those things that are not required but should be done for minimum safety.

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 Electrical codes and standards
• Electrical products are generally required to pass
standardized tests for safe usage
• Underwriters’ laboratories identified with UL symbol. It
ensures that the acceptable safety level is being maintained.
• Main purpose; to establish, maintain and operate laboratories
for the investigation of materials, devices, products
equipment, construction methods and system with regards to
hazards affecting life and property.(for minimum safety)
• Standards established by National Electrical Manufacturers
Association (NEMA) standard provide practical info
concerning the rating, testing performance and manufacturer
of motor control devices.
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 How to be safe
• Recognize hazard
• Evaluate risk
• Control hazards

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Recognize hazard

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Evaluate risk

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Control Hazard

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 Work Practices
• Employees and others working with electric
equipment need to use safe work practices.
– Plan your work by yourself and with others.
• Allows you to coordinate your work and take advantage
of what others know about identifying and controlling
hazards.
– Lock out and Tag out circuits and equipment.
• Shut off the circuit.
• Lock and tag out the circuit at the distribution panel.
• Test the circuit to make sure it’s de-energized.
 Work Practices
– Do not work in wet conditions.
– Avoid overhead power lines.
• You should be at least 10 feet away from high-voltage
transmission lines.
– Use proper wiring and connectors
• Avoid overloading circuits.
• Test GFCI’s monthly.
• Make sure switches and insulation are in good
condition.
• Never use a three prong plug with the third prong
broken off.
 Work Practices
– Use and maintain tools properly.
• Inspect tools before using them.
• Damaged tools must be removed from service.
• Keep tool and cords away from heat, oil and sharp
objects.
– Using appropriate personal protective equipment
• Wear safety glasses to avoid eye injury.
• Wear proper foot protection.
• Wear a hard hat.
• Follow the manufacturer’s directions for
cleaning/maintaining PPE.
 How to Respond/Report a Problem
• Do not panic; remain calm
• In the event of a personal injury:
– Call 1122 immediately
– If a person is being shocked, turn of the source of
electricity
– Do not touch someone being shocked
– Remove the person away from the electrical source
using a non-conductive material
– Call Security and Notify your supervisor
 How to Respond/Report a Problem

• In the event of an electrical fire:

– Activate the fire alarm system
– Do not use a Type A, water extinguisher
– If you know how to use an extinguisher, use a CO2
or dry chemical fire extinguisher
– Alert everyone in the area to evacuate
– Notify Security
– If you are not sure about using a fire extinguisher,
leave the area and close any doors behind you
– Wait for the Fire Dept. personnel to arrive
 Supervisor Responsibilities

• Review project carefully with your workers, unless they

are routine assignments
• Emphasize safety practices
• Train workers on area-specific policies and procedures
• Check your employees’ work practices to ensure
compliance
• Check the final product to ensure that no deficiencies
exist
• Provide the appropriate disciplinary measures for poor
electrical safety practices.
 Employee Responsibilities

• Review each project carefully with your

supervisor
• Become thoroughly familiar with your
assignments
• Only perform work in which you are trained
• If at all in doubt, ask questions
• Have your supervisor review your completed
project
• Follow your supervisor’s instructions
 Employee Responsibilities (Continued)

• Follow safe work practices

• Make sure lines are de-energized before your
work on them
• Wear any required PPE
• Alert your co-workers to any unsafe work
practices
• Report all problems to your supervisor
• Know what to do in the event of an emergency