DESIGN AND INSTALLATION OF ELECTRICAL EQUIPMENT OF GENERAL PURPOSE MACHINE TOOLS Design and installation of electrical equipment of general pur- pose machine tools should ensure uniform design and installation procedure, ease of maintenance and safety of personnel and equipment. Certain basic information necessary for the designers are dealt with in this chapter. However for a detailed code of practice refer- ence should be made to any of the following standards: IS 1356(1); BS 2771; CSN 34 1630, VDE 0113 or JIC EGP1.Connections to supply network The electrical equipment is as far as possible connected to a single source of power supply by an ON-OFF switch. Other voltages if required are obtained from apparatus such as transformers, re- ctifiers, etc., forming an integral part of the electrical equipment of the machine tools. In the OFF position of the switch all electrical equipment are disconnected from the supply, except those which may cause danger if disconnected, such as magnetic chuck, brake system, etc. Sometimes the switch is locked in the OFF position to prevent unauthorised persons operating the machine. Some switches have the provision of being interlocked with the door of the electrical cabinet such that the door cannot be opened in the ON position of the switch. The current and voltage ratings of the switch are decided by the connected load.Emergency stopping device In addition to the mains isolating switch it may also be required to provide an emergency stopping device which is clearly visible and easily accessible to stop the machine tool as quickly as possible in order to avoid danger to the operator or equipment. This is'a red-coloured) mushroom push button and provided in as many places as required in machine tools with multi control stations. . However circuits for magnetic chucks, braking systems, etc. are not to be interrupted by the emergency stopping device. With- drawal motions required for safety may also be initiated by actuat- ing the emergency stopping device.Protective measures The machine tool motors require short-circuit protection, no- voltage protection and overload protection.732 DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT CONTROL CIRCUITS Control circuits control the switching-on pattern for the cont- actors to switch ON or OFF the electric motors as well as control the actuating elements such as solenoid valves, electro-magnets, electro-magnetic clutches.etc. ; It is suggested to use a control transformer having separate windings and connected to the load side of the supply disconnecting Switch. For ac control circuits supplied by a transformer the recom- mended secondary voltages are 110, 220 and 240 volts at 50 Hz. For dc control circuits, the recommended voltages are 24, 48, 110 and 220 volts. To prevent earth faults, it is recommended that one side of the control circuit be earthed. Design of control circuit The design of the electrical control circuit requires a thorough understanding of the working of the complete machine. Safety of the operator and the machine should always be remembered and it should be ensured that damage in case of failure of any signalling device is a minimum. A few typical cases of circuit design and conditions for inter- locking are given below; the list is not comprehensive, but is given only for guidance. An example of a typical circuit diagram is given in Fig. 229. The symbols used in the circuit are covered in Table 341. Opposing motions interlocked Starters, relays, contactors and solenoids which are mechani- cally interlocked are also electrically interlocked to prevent simul- taneous energization. DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT 733 Movement initiation by limit switches Control circuits are so designed that, when the machine tool is not in its working cycle, the actuation of any limit-switch does not initiate the movement of any part of the machine tool. Covers and doors interlocked Hinged covers may be interlocked with the machine tool con- trol to prevent operation of the machine tool while the cover is left open. Spindle drive interlocked with feed Interlocking is provided to ensure that the spindle drive motor is switched on before the tool is driven into the workpiece while in the automatic cycle. Non-repetition of the cycle On all equipment where automatic repetition of the cycle is dangerous, the circuit is so designed that this repetition does not occur and the machine is brought to a total stop at the end of the cycle without requiring the action of the operator. Reverse current braking When reverse current braking is used on a motor, all measures are taken to avoid the motor re-starting in the opposite direction at the end of braking, when this inversion may endanger the personnel or damage the workpiece; in such cases the use of a device operating exclusively as a function of time is not allowed. Furthermore, all measures are taken to prevent false starting of the motor caused by the rotation of the motor shaft. STOP functions are generally initiated through de-energization rather than energization of control devices wherever possible. One station for motor starting Only one station is made effective at any time ror starting all motors concurrently. However multiple STOP stations may be used. Control enclosures and compartments Control enclosures and compartments are to be so enclosed as to give adequate protection against ingress of dust, oil, coolant or chips and against machanical damage. Alll control devices like con- tactors, fuses, etc., are front mounted on a rigid metal panel and it should be possible to remove the entire panel through the opening in the enclosure. The control devices in the enclosure are so instal- led that they are readily accessible when the doors or covers are opened.734 DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT All connection terminals should be easily accessible and lo- cated at least 200 mm from the floor or servicing level. Apparatus requiring easy access for maintenance and adjust- ment are not to be situated below 400mm and above 2000 mm from the servicing level. There shall be no opening between compartments containing electrical apparatus and reservoirs holding coolant, lubricating or hydraulic oils. Mechanical parts to which access is necessary during the nor- mal operation of the machine tool and moving parts (rotating shafts) are not to be housed in control enclosures and compart- ments. Heat generating components like fesistors, valves, etc., are so located, that the temperature rise of components inside the control enclosure is kept within permissible limits, otherwise the available space can be divided into a ventilatingsection containing the heat generating components and a protected section containing the other components.734 DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT Control and Operating Devices CONTROL DEVICES Allcontrol devices external to the control enclosure such as limit switches, magnetically operated valves, pressure switches, etc., are So mounted that they are readily accessible and located in Teasona- bly dry and clean locations and free from accidental operation by normal movement of machine components or operator. Limit switches or position sensors are so mounted that they will not be damaged in the event of accidental overtravel. Pipe lines, tubing or devices for handling air, gases or liquids must not be located in electrical control enclosures or compart- ments. OPERATING DEVICES The operating devices should be mounted in a dust and oil free location and within easy reach of the machine tool operator in his normal working position. PUSH- BUTTONS General Push-buttons are mounted so that the movement of the buttons is either in a horizontal plane or does not exceed 45° from the horizontal. All push-buttons other than STOP buttons should be shrouded to avoid the danger of unintentional operation. DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT 735 Colour of push-button | The recommended colours for push-buttons used on machine tools are indicated in Table 322. Illuminated push buttons ee The recommended colours and functions of illuminated push buttons are indicated in Table 323. SIGNALLING LAMPS . The recommended colours of signalling lamps used on machine tools are indicated in Table 324. ‘Table 322 Colour and functions of push-buttons Ean pa Red Stop — Stop of one or several motors — Stop of machine elements — De-energizing of magnetic chucks — Stop of the cycle (if the operator pushes the button during a cycle, the machine stops after the relev- ant cycle is completed) General stop. Return of machine elements to the starting point of the cycle, if the cycle has not been completed. Start of a return motion not in the usual operat- ing sequence or Start of an operation in- tended to avoid danger- ous conditions Pressing the yellow push-button may override other functions which have been selected previously. — Energizing of the control circuits — Start of one or several motors for auxiliary functions Start (preparation) Start of machine elements — Energizing of magnetic chucks — Start of a cycle or a partial sequ- ence — Inching, jogging —— Control of auxiliary functions which are not directly related to the working cycle Reset of protective relays (if the same button is used for STOP, it shall be RED), Start (execution) Any function not co- vered by the above col- ours736 DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT Table 323 Colour and functions of illuminated push-buttons _— Significance Function and mode of the lighted of the button button STOP (see ] note 2) and in some in- stances See note 1 RESET (only if this same button is also used for STOP) Examples of application and remarks Some value (current, temperature) is ap- proaching its permis- sible limit. Pressing the yellow push-button Start of an operation . . in Attention or caution _| 'Mended to avoid may override other dangerous | functions, which have conditions been selected previ- ously. J r t — Start of one or several motors for auxiliary Start after functions . - authorisation | — Start of machine elements Machine or unit ready by the — Energizing of magne- for operation lighted but- tic chucks or plates ton — Start of a cycle or a partial sequence (see also note 3) Indication or order to the Any func- operator to perform a cer- to . tion not co- tain task, for example to Any signification not | veredbythe | make an adjustment (after covered by the above | above col- having fulfilled this re- colours and by white jours and by | quirement, he presses the white button as an acknowledge- | ment). Permanent confirmation Engergizing of an auxiliary thatacircuit has been Closing of a | circuit not related to the energized circuit | working cycle or or Start or preselection that a function or a | Start or pre- of direction of feed movement has _ been | Selection motion started or preselected | _| of speeds, ete. Notes: 1, The use of RED illuminated push-buttons is not recommended. 2. Emergency stop buttons are never illuminated push-buttons. 3. For iachiug and jogging, non-illuminated black push-buttons should be used.DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT 737 Colour Yellow (Amber) Green White (clear) Significance ‘Abnormal conditions requiring immediate ac- tion by the operator (see notes 1 and 2) Attention or caution (see note 1) Machine ready Circuit energized Normal conditions Any signification not covered by the above colours ‘Table 324 Colour and significance of signalling lamps Order to stop the machine im- mediately (for example because of an overload) or To indicate that a protective device has stopped the machine (for example be- cause of an overload, overtravel or another failure) Some value (current, temperature) is approaching its permissible limit or Automatic cycle running Machine ready for operation; all necessary auxiliaries functioning, units in starting position and hydraulic pres- sure or output voltage of a motor- generator in the specified range, etc. Cycle completed and machine ready to be restarted. Main switch in ON position (see note 2) — Choice of the speed or the direc- tion of rotation Auxiliaries not related to the working cycle are functioning. — Selector switch in SET UP position’ ‘A unit in forward position — Microfeed of a carriage or unit For the significations Abnormal conditions requiring immediate action ot ‘Attention, a flashing signal of the appropriate colour may be used ac- ‘companied by an audible signal, if desired. For Main switch in ON position, RED may be used if the signalling lamp is not on the operator's control station. The cables and wires used must be suitable for the loads they supply taking into account current, voltage drop, etc. Grade of cables When the voltage to earth exceeds 250 volts, the cable must be of 650/1100 volts grade and when the voltage to earth does not exceed 250 volts, either 250/440 volts grade or 650 volts grade may be used. For mechanical reasons, the cross-sections used must not be Jess than those indicated in Table 325.\ 738 DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT Wiring methods and practices: Conductors of different colours are selected as indicated in Table 326. All wiring, other than those of suitably protected cables, outside control enclosures and compartments, are generally laid in conduits or raceways. Flexible cables are generally used for connections to moving or adjustable machine components in which electrical equipment is incorporated. . Conductors are identified at each termination by marking with a number to correspond with the circuit diagram. Table 325 Minimum cross section of copper conductors Type of connection Conductors outside control enclosures and compartments: i) for stranded conductors ii) for solid conductors (used only in exceptional cases) 2 | Multi-core cables outisde control enclosures and compartments i) for two and more cores in general ii) for connecting very low current circuits (electronic logic and similar circuits) a) cables with two or more cores b) cables with three or more cores ¢) screened two-core cables terminals of such cables shall be fixed in such a manner as to prevent strain on the ends of conductors. iii) for flexible cables and connecting parts subject to frequent movement Conductors inside control enclosures and compartments: i) in general ii) for very low current circuits (electronic logic and similar circuits) Conductors with smaller cross-section may be used only where sizes indicated above affect the proper functioning of the equipment. Note: Table 326 Colour coding of conductors Type of circuit ac or de power circuits ac control circuit de control circuit Equipment earthing conductor Earthed circuit conductorDESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT 739 Terminals on terminal blocks are permanently marked to correspond with the identificatien shown on the circuit diagram and are conveniently numbered. It is recommended that on complex machine tools, when several switching devices (such as limit switches, push-buttons, etc.) are connected in series and/or parallel, the conductors between them shall be returned to terminals forming intermediate test points conveniently placed and adequately protected. These test points are shown on the relevant diagrams. Earthing It is necessary to earth all electrical elements such as motors, switches, etc., which may become dangerously live in case of faults. In order to earth these, a main earthing terminal must be provided close to the main input terminals. It should be of such a size as to enable the connection of an earth continuity conductor of the following cross-section. Cross-section for which the main earthing terminal has to be dimensioned ‘Cross-section of the main conductors supplying the equipment Upto and including 16 mm* Larger than 16 mm? Equal to that of the main conductor At least 50% of the main conductor with a min. of 16 mm? The internal earth connection wires within the machine tool must all be connected to the main earthing terminal. Local lighting of the machine For local lighting in machine tools, adjustable lamps preferably of low voltage are used.DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT 739 Tests Eventhough the individual electrical elements are tested by the manufacturers to satisfy the specifications, the complete electrical system of the machine tool is tested for proving its suitability. The following tests are generally conducted for this purpose. INSULATION RESISTANCE TEST The insulation resistance measured with dc voltage of 500 volts between each conductor of the main circuits, the individual conductors of the control circuits and earthed frame should not be less than one megaohm. When the control circuits are not directly connected to the main circuits, separate tests are conducted between the main740 DESIGN, INSTALLATION OF ELECTRICAL EQUIPMENT circuits and the earthed frame, between the main circuits and the control circuits, and between the control circuits and the earthed frame. VOLTAGE TEST All the equipment are subjected to a voltage test of one minute duration by applying a test voltage as defined below between the short-circuited conductors of the main circuits, including any control circuits directly connected to the main circuits and the earthed frame. The test voltage shall be atleast equal to 85% of the lowest test voltage to which all components are already tested before assembly on the machine, with a minimum of 1500 V. This voltage is supplied from a transformer with a rating of atleast 500 VA Components which are not designed to withstand such high test voltages (rectifiers, capacitors, electronic apparatus, etc.) are disconnected during the test. Any radio interference capacitors fitted between parts normally alive and accessible metal parts are not disconnected and should withstand the above test. RESISTANCE TO EARTH: The resistance between the main earth terminal and any metallic part of the machine containing electrical equipment should not exceed 0.1 Ohm. OPERATING TEST: No-load operating test: With the electrical equipment normally energized within the prescribed condition (for example, maximum variation of supply voltage) it should be proved that the sequence of operations is normal. In particular, the correct operation of the emergency stopping device should be checked. This test must be performed on each machine tool. On-load operating test When the machine tool operates under normal load, continuously or at the duty agreed to between the purchaser and the manufacturer, the temperature rise of all the equipment above the ambient temperature in which the machine is intended to operate should not exceed that permitted by the Standards appropriate for the apparatus concerned. The correct operation of all the equipment must be proved and ELECTRIC MOTORS 741 in particular, that interruption and restoration of power supply does not endanger personnel or adversely affect the equipment. It is essential to prove that the emergency stopping of motors under load by means of the stopping devices occurs safely.ELECTRIC MOTORS 741 Safety practices The safety of machine tool operation is a thing which should be assured by each and every one connected with the machine tool, the designer, the maintenance engineer, the operator and the electrician. Some of the safety practices concerning the electrical equipment are as follows. Machine tools be suitably designed to prevent undesirable hazardous movements of parts due toa drop in the supply voltage or an interruption to the electric supply. When using electrically operated clamping unit, suitable equipment be provided to stop the machine if there is a drop in the clamping force due to an undervoltage or interruption of the electric supply. The control elements such as push-buttons, switches, etc., be properly located to ensure that the operator is not endangered by the hazardous moving parts while operating the controls. Control elements of the machine must be guarded against unauthorised operation by providing suitable locking units necessitating the use of special tools.