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Rules of thumb
Source: MIL-STD-882 & JOINT SOFTWARE SYSTEMS SAFETY ENGINEERING HANDBOOK Version 1.0 Published August 27, 2010
Booster Pump
City Water
HOT WATER RECIRCULATION PUMP
EFFLUENT PUMP
Effluent Sewers in the United States
SUMP PUMP
Schematic
CONDENSATE
PUMP
IRRIGATION PUMP
FOUNTAIN PUMP
UL 1081
Wading Pool
CONTRACTOR PUMP
UNITY PUMP
You Know Too Much.
3 Definitions
4 Instructions Provided With the Pump
Now You Know That
Minimum thicknesses of enclosure Polymeric Material


                 Polymeric Material           The encapsulation Epoxy as watertight Enclosure                      A one-piece, molded coil form in contact with water

                Minimum Thickness                                  1/8 inch (3.2 mm)                                                   1/32 inch (0.8 mm)




                                                                  Minimum thicknesses of enclosure metal


                                                                                       At curved, ribbed, or otherwise reinforced
                                                                                      surfaces and at surfaces of a shape or size,          At surfaces to which a         At surfaces intended
                                                        At unreinforced, flat        or both, to provide the necessary mechanical           wiring system is to be                  for
                    Metal                               surfaces in general                             strength                            connected in the field             outdoor use
Cast Metal    Nonferrous Die-cast metal
                          such as Aluminum-
                          , Magnesium-,                  5/64 inch (2.0 mm)                         3/64 inch (1.2 mm)                                  -                           -
                          Zinc- or Copper-
                          based alloy
              Ferrous     Cast malleable
                                                         3/32 inch (2.4 mm)                            1/16 (1.6 mm)                                    -                           -
                          iron
              Ferrous or  Other cast metal
                                                          1/8 inch (3.2 mm)                         3/32 inch (2.4 mm)                                  -                           -
              Nonferrous
Sheet         Ferrous     Uncoated sheet
                                                        0.026 inch (0.6 mm)                                                                  0.032 inch (0.81 mm)         0.032 inch (0.81 mm)
Metal                     steel
                          Galvanized
                                                        0.029 inch (0.74 mm)                                                                 0.034 inch (0.86 mm)         0.034 inch (0.86 mm)
                          sheet steel
              Nonferrous Sheet aluminum
                                                        0.036 inch (0.91 mm)                                                                 0.044 inch (1.2 mm)                   -

                              Sheet copper or
                                                         0.033 inch (0.84 mm)                                                               0.043 inch (1.09 mm)                   -
                              sheet brass
       - Surfaces in relatively small areas or surfaces that are curved, ribbed, or otherwise reinforced may be less than the specifications in the first column of thicknesses.
A – Region to be shielded by barrier. This will consist of the entire component if it is not otherwise shielded, and will
consist of the unshielded portion of a component which is partially shielded by the component enclosure or equivalent.
B – Projection of outline of component on horizontal plane.
C – Inclined line which traces out minimum area of barrier. When moving, the line is always:
                         1) Tangent to the component,
                         2) 5 degrees from the vertical, and
                         3) Oriented so that the area traced out on a horizontal plane is maximum.
D – Location (horizontal) and minimum area for barrier. The area is that included inside the line of intersection traced
out by the inclined line C and the horizontal plane of the barrier.
Galvanization (or galvanisation)

   classically refers to any of several electrochemical processes named after
   the Italian scientist Luigi Galvani.

   Now the term generally refers to an electrodeposition process used to
   add a thin layer of another metal to an item made of steel, in order to
   prevent rusting.

   More recently, though, the term has been broadened in common usage
   to include applying a protective metallic coating to an underlying piece
   of metal, using a process called hot-dip galvanization, which produces
   similar results, but which does not employ electrochemical deposition.
A zinc coating, other than that provided on hot-dipped, mill-
galvanized sheet steel(ASTM A653/A653M)
Phosphate          conversion coating are used on steel parts
for corrosion resistance, lubricity, or as a foundation for
subsequent coatings or painting. It serves as a conversion
coating in which a dilute solution of phosphoric acid and
phosphate salts is applied via spraying or immersion and
chemically reacts with the surface of the part being coated to
form a layer of insoluble, crystalline phosphates.
Phosphate coatings are often used to provide corrosion
resistance, however, phosphate coatings on their own do not
provide this because the coating is porous. Therefore, oil or
other sealers are used to achieve corrosion resistance.
Black Oxide            (historical uses of black oxide, Bluing) is a
conversion coating formed by a chemical reaction produced when
parts are immersed in the alkaline aqueous salt solution operated at
approximately 285 °F (141 °C). The reaction between the iron of the
ferrous alloy and the hot oxide bath produces a magnitite (Fe3O4) on
the actual surface of the part. It is possible to oxidize non-ferrous
metals under suitable conditions to form black oxides.

Black oxide provides minimal protection against corrosion, unless
also treated with a water-displacing oil to reduce wetting and
galvanic action.

The oldest and most widely used specification for hot black oxide is
MIL-DTL-13924, which covers four classes of processes for different
substrates. Alternate specifications include AMS 2485, ASTM D769,
and ISO 11408.
Conversion coatings are coatings for metals where the part surface is
converted into the coating with a chemical or electro-chemical process.
Examples include chromate conversion coatings, phosphate conversion
coatings, bluing, black oxide coatings on steel, and anodizing. They are used
for corrosion protection, increased surface hardness, to add decorative color
and as paint primers. Conversion coatings may be very thin, on the order of
0.00001". Thick coatings, up to 0.002", are usually built up on aluminium
alloys, either by anodizing or chromate conversion.

Passivation is the process of making a material "passive", usually by the
deposition of a layer of oxide on its surface. In air, passivation affects the
properties of almost all metals–notable examples being aluminium, zinc,
titanium, and silicon. In the context of corrosion, passivation is the
spontaneous formation of a hard non-reactive surface film that inhibits further
corrosion. This layer is usually an oxide or nitride that is a few nanometers
thick.
Cadmium plating
Cadmium plating (Electroplating) is under scrutiny because of the
environmental toxicity of the cadmium metal. However, cadmium
plating is still widely used in some applications such as aerospace
fasteners and it remains in military and aviation specs. Cadmium
plating (or "cad plating") offers a long list of technical advantages
such as excellent corrosion resistance even at relatively low
thickness and in salt atmospheres, softness and malleability,
freedom from sticky and/or bulky corrosion products, galvanic
compatibility with aluminum, freedom from stick-slip thus allowing
reliable torquing of plated threads, can be dyed to many colors and
clear, has good lubricity and solderability, and works well either as
a final finish or as a paint base.
Sand-cast
       The most widely used
       casting process,
       utilizes expendable
       sand molds to form
       complex metal parts
       that can be made of
       nearly any alloy.
Table of electrochemical potentials
IEC 60364 LOW-VOLTAGE ELECTRICAL INSTALLATIONS

                                                                  TN-C

                                                         TN       TN-S

                                      T                           TN-C-S
IEC classifications of                                   TT
Power     Distribution
network Systems

                                       I                  IT

               Based on the Earthing of transformer secondaries
nomenclature
Typical U.S. Power Distribution network




         Three-phase                   Single phase                   Three-phase
         transformer secondary          transformer secondary         transformer secondary
         (U.S. commercial 120/240 V)   (U.S. residential 240/120 V)   (U.S. commercial 208/120 V
                                                                      and 480/277 V)
                                                                      (Europe et al 230/400 V)
US RESIDENTIAL ELECTRICAL BRANCH CIRCUITS



                           TN System




                                   PEN (protective earthing neutral)
Electrical System
NFPA 70, National Electrical Code
立




Stud
       柱




           Residential
Industry/
Commercial
Table 400.4 Flexible Cords and Cables
S    Hard Service (600 V)
SJ   Hard Service, Junior (300 V)
E    Thermoplastic Elastomer (After first letter)
T    Thermoplastic (After first letter)
-    No T or E means Thermoset by default.
O    Oil-resistant. Single “O” means outer jacket only is oil resistant; double “O”
     means both outer jacket and inner conductor insulation are oil resistant
W    Weather-resistant. (Both Water and Sunlight resistant, suitable for outdoor use)
H    Heater
V    Vacuum Cleaner
E    Elevator (As first letter)
EV   Electric Vehicle
T    Tinsel (As first letter)
P    Parallel
NI   Non – integral
-1   Insulation thickness for Parallel cords, thinnest to thickest. Actual insulation
–2   thickness varies with cord type and AWG size
-3
Branch Circuit. The circuit conductors
between the final overcurrent device
protecting the circuit and the outlet(s).
NEC RECEPTACLE RULES SHAPE THE POWER SUPPLY
CORD LENGTH OF APPLIANCE IN UL STANDARDS.
If > 50 % , marking Connect Only To A
Dedicated Branch Circuit.applicable.
SET-SCREW
SOLDER LUG
WIREING BINDING SCREW
WIREING BINDING SCREW
                                                                     Threads per inch                                 Tap drill size
          Nominal          Minimum
Size of                                    Major diameter,                                        Major                                Extra
          diameter,   tightening torque,                     Coarse      Fine    Extra Fine                  Coarse        Fine
screw                                            in.                                          diameter, mm                             Fine
             mm              N.m                              UNC        UNF       UNEF                       UNC          UNF
                                                                                                                                       UNEF
 No. 6        3.5            1.30             0.1380            32        40                     3.5052       #36          #33
 No. 8        4.2            1.81             0.1640            32        36                     4.1656       #29          #29
 No. 10       4.8            2.49             0.1900            24        32                     4.8260       #25          #21
 No. 12       5.5            3.95             0.2160            24        28            32       5.4864       #16          #14
  1/4         6.4            6.78               1/4             20        28            32       6.3500        #7           #3
ASME International (American Society of Mechanical Engineers)
B18.6.3-1999
Machine Screws and Machine Screw Nuts
An upturned lug or cupped washer


Source: IEC 60730, Figure 10 SCREW TERMINALS AND STUD TERMINALS
Source: IEC 60730, Figure 13B LUG TERMINALS
Split   Serrated
The intent is to ensure
enough slack for the
terminal connections to be
made easily.
ARTICLE 314— OUTLET, DEVICE, PULL,
AND JUNCTION BOXES; CONDUIT
BODIES;FITTINGS; AND HANDBOLES

314.16 Number of Conductors in
Outlet, Device, and
Junction Boxes, and Conduit Bodies.

(B) Box Fill Calculations.
                             UL 778
ARTICLE 430— MOTORS, MOTOR CIRCUITS,
AND CONTROLLERS

430.12 Motor Terminal Housings.
Table 430.12(B)
                            UL 778
ARTICLE 430— MOTORS, MOTOR CIRCUITS,
AND CONTROLLERS

430.12 Motor Terminal Housings.
Table 430.12(C)(1) and Table
430.12(C)(2)



                           UL 778
Conduit
Electrical Rigid Metal Conduit (RMC)   Intermediate Metal Conduit (IMC)   Electrical Metallic Tubing (EMT)




 RMC is the heaviest-weight and thickest-wall steel conduit.

 IMC has a thinner wall than RMC and weighs about one-third less than RMC.

 EMT is the lightest-weight and thinnest-wall unthreaded steel conduit and also
  commonly called thin-wall conduit.
14 Current-Carrying or Live Parts
15 Insulating Material
IEC 60417 symbol 5019
Dual Element Fuse
You should know that!
20 Overload-Protective Devices
Class 2
NFPA 70
NATIONAL ELECTRICAL CODE
Well, Very diverse.
25 Sharp Edges
26 Materials
27 Stability
28 Polymeric Motor Supports
30 Pressure-Relief Devices
UL 778  motor operated pump
UL 778  motor operated pump
UL 778  motor operated pump
UL 778  motor operated pump
UL 778  motor operated pump
UL 778  motor operated pump
UL 778  motor operated pump
UL 778  motor operated pump

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UL 778 motor operated pump

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  • 48. R emember the f ollowing Rules of thumb
  • 49. Source: MIL-STD-882 & JOINT SOFTWARE SYSTEMS SAFETY ENGINEERING HANDBOOK Version 1.0 Published August 27, 2010
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  • 115. Effluent Sewers in the United States
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  • 216. You Know Too Much.
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  • 222. 4 Instructions Provided With the Pump
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  • 261.
  • 262. Now You Know That
  • 263.
  • 264.
  • 265. Minimum thicknesses of enclosure Polymeric Material Polymeric Material The encapsulation Epoxy as watertight Enclosure A one-piece, molded coil form in contact with water Minimum Thickness 1/8 inch (3.2 mm) 1/32 inch (0.8 mm) Minimum thicknesses of enclosure metal At curved, ribbed, or otherwise reinforced surfaces and at surfaces of a shape or size, At surfaces to which a At surfaces intended At unreinforced, flat or both, to provide the necessary mechanical wiring system is to be for Metal surfaces in general strength connected in the field outdoor use Cast Metal Nonferrous Die-cast metal such as Aluminum- , Magnesium-, 5/64 inch (2.0 mm) 3/64 inch (1.2 mm) - - Zinc- or Copper- based alloy Ferrous Cast malleable 3/32 inch (2.4 mm) 1/16 (1.6 mm) - - iron Ferrous or Other cast metal 1/8 inch (3.2 mm) 3/32 inch (2.4 mm) - - Nonferrous Sheet Ferrous Uncoated sheet 0.026 inch (0.6 mm)  0.032 inch (0.81 mm) 0.032 inch (0.81 mm) Metal steel Galvanized 0.029 inch (0.74 mm)  0.034 inch (0.86 mm) 0.034 inch (0.86 mm) sheet steel Nonferrous Sheet aluminum 0.036 inch (0.91 mm)  0.044 inch (1.2 mm) - Sheet copper or 0.033 inch (0.84 mm)  0.043 inch (1.09 mm) - sheet brass  - Surfaces in relatively small areas or surfaces that are curved, ribbed, or otherwise reinforced may be less than the specifications in the first column of thicknesses.
  • 266.
  • 267.
  • 268. A – Region to be shielded by barrier. This will consist of the entire component if it is not otherwise shielded, and will consist of the unshielded portion of a component which is partially shielded by the component enclosure or equivalent. B – Projection of outline of component on horizontal plane. C – Inclined line which traces out minimum area of barrier. When moving, the line is always: 1) Tangent to the component, 2) 5 degrees from the vertical, and 3) Oriented so that the area traced out on a horizontal plane is maximum. D – Location (horizontal) and minimum area for barrier. The area is that included inside the line of intersection traced out by the inclined line C and the horizontal plane of the barrier.
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  • 290. Galvanization (or galvanisation) classically refers to any of several electrochemical processes named after the Italian scientist Luigi Galvani. Now the term generally refers to an electrodeposition process used to add a thin layer of another metal to an item made of steel, in order to prevent rusting. More recently, though, the term has been broadened in common usage to include applying a protective metallic coating to an underlying piece of metal, using a process called hot-dip galvanization, which produces similar results, but which does not employ electrochemical deposition.
  • 291.
  • 292.
  • 293.
  • 294. A zinc coating, other than that provided on hot-dipped, mill- galvanized sheet steel(ASTM A653/A653M)
  • 295.
  • 296. Phosphate conversion coating are used on steel parts for corrosion resistance, lubricity, or as a foundation for subsequent coatings or painting. It serves as a conversion coating in which a dilute solution of phosphoric acid and phosphate salts is applied via spraying or immersion and chemically reacts with the surface of the part being coated to form a layer of insoluble, crystalline phosphates. Phosphate coatings are often used to provide corrosion resistance, however, phosphate coatings on their own do not provide this because the coating is porous. Therefore, oil or other sealers are used to achieve corrosion resistance.
  • 297. Black Oxide (historical uses of black oxide, Bluing) is a conversion coating formed by a chemical reaction produced when parts are immersed in the alkaline aqueous salt solution operated at approximately 285 °F (141 °C). The reaction between the iron of the ferrous alloy and the hot oxide bath produces a magnitite (Fe3O4) on the actual surface of the part. It is possible to oxidize non-ferrous metals under suitable conditions to form black oxides. Black oxide provides minimal protection against corrosion, unless also treated with a water-displacing oil to reduce wetting and galvanic action. The oldest and most widely used specification for hot black oxide is MIL-DTL-13924, which covers four classes of processes for different substrates. Alternate specifications include AMS 2485, ASTM D769, and ISO 11408.
  • 298. Conversion coatings are coatings for metals where the part surface is converted into the coating with a chemical or electro-chemical process. Examples include chromate conversion coatings, phosphate conversion coatings, bluing, black oxide coatings on steel, and anodizing. They are used for corrosion protection, increased surface hardness, to add decorative color and as paint primers. Conversion coatings may be very thin, on the order of 0.00001". Thick coatings, up to 0.002", are usually built up on aluminium alloys, either by anodizing or chromate conversion. Passivation is the process of making a material "passive", usually by the deposition of a layer of oxide on its surface. In air, passivation affects the properties of almost all metals–notable examples being aluminium, zinc, titanium, and silicon. In the context of corrosion, passivation is the spontaneous formation of a hard non-reactive surface film that inhibits further corrosion. This layer is usually an oxide or nitride that is a few nanometers thick.
  • 299.
  • 300. Cadmium plating Cadmium plating (Electroplating) is under scrutiny because of the environmental toxicity of the cadmium metal. However, cadmium plating is still widely used in some applications such as aerospace fasteners and it remains in military and aviation specs. Cadmium plating (or "cad plating") offers a long list of technical advantages such as excellent corrosion resistance even at relatively low thickness and in salt atmospheres, softness and malleability, freedom from sticky and/or bulky corrosion products, galvanic compatibility with aluminum, freedom from stick-slip thus allowing reliable torquing of plated threads, can be dyed to many colors and clear, has good lubricity and solderability, and works well either as a final finish or as a paint base.
  • 301.
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  • 307. Sand-cast The most widely used casting process, utilizes expendable sand molds to form complex metal parts that can be made of nearly any alloy.
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  • 332. IEC 60364 LOW-VOLTAGE ELECTRICAL INSTALLATIONS TN-C TN TN-S T TN-C-S IEC classifications of TT Power Distribution network Systems I IT Based on the Earthing of transformer secondaries
  • 334. Typical U.S. Power Distribution network Three-phase Single phase Three-phase transformer secondary transformer secondary transformer secondary (U.S. commercial 120/240 V) (U.S. residential 240/120 V) (U.S. commercial 208/120 V and 480/277 V) (Europe et al 230/400 V)
  • 335. US RESIDENTIAL ELECTRICAL BRANCH CIRCUITS TN System PEN (protective earthing neutral)
  • 336.
  • 337. Electrical System NFPA 70, National Electrical Code
  • 338.
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  • 340. 立 Stud 柱 Residential
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  • 348. Table 400.4 Flexible Cords and Cables S Hard Service (600 V) SJ Hard Service, Junior (300 V) E Thermoplastic Elastomer (After first letter) T Thermoplastic (After first letter) - No T or E means Thermoset by default. O Oil-resistant. Single “O” means outer jacket only is oil resistant; double “O” means both outer jacket and inner conductor insulation are oil resistant W Weather-resistant. (Both Water and Sunlight resistant, suitable for outdoor use) H Heater V Vacuum Cleaner E Elevator (As first letter) EV Electric Vehicle T Tinsel (As first letter) P Parallel NI Non – integral -1 Insulation thickness for Parallel cords, thinnest to thickest. Actual insulation –2 thickness varies with cord type and AWG size -3
  • 349. Branch Circuit. The circuit conductors between the final overcurrent device protecting the circuit and the outlet(s).
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  • 356.
  • 357. NEC RECEPTACLE RULES SHAPE THE POWER SUPPLY CORD LENGTH OF APPLIANCE IN UL STANDARDS.
  • 358.
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  • 363. If > 50 % , marking Connect Only To A Dedicated Branch Circuit.applicable.
  • 364.
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  • 374. WIREING BINDING SCREW Threads per inch Tap drill size Nominal Minimum Size of Major diameter, Major Extra diameter, tightening torque, Coarse Fine Extra Fine Coarse Fine screw in. diameter, mm Fine mm N.m UNC UNF UNEF UNC UNF UNEF No. 6 3.5 1.30 0.1380 32 40 3.5052 #36 #33 No. 8 4.2 1.81 0.1640 32 36 4.1656 #29 #29 No. 10 4.8 2.49 0.1900 24 32 4.8260 #25 #21 No. 12 5.5 3.95 0.2160 24 28 32 5.4864 #16 #14 1/4 6.4 6.78 1/4 20 28 32 6.3500 #7 #3 ASME International (American Society of Mechanical Engineers) B18.6.3-1999 Machine Screws and Machine Screw Nuts
  • 375.
  • 376. An upturned lug or cupped washer Source: IEC 60730, Figure 10 SCREW TERMINALS AND STUD TERMINALS
  • 377. Source: IEC 60730, Figure 13B LUG TERMINALS
  • 378. Split Serrated
  • 379. The intent is to ensure enough slack for the terminal connections to be made easily.
  • 380. ARTICLE 314— OUTLET, DEVICE, PULL, AND JUNCTION BOXES; CONDUIT BODIES;FITTINGS; AND HANDBOLES 314.16 Number of Conductors in Outlet, Device, and Junction Boxes, and Conduit Bodies. (B) Box Fill Calculations. UL 778
  • 381. ARTICLE 430— MOTORS, MOTOR CIRCUITS, AND CONTROLLERS 430.12 Motor Terminal Housings. Table 430.12(B) UL 778
  • 382. ARTICLE 430— MOTORS, MOTOR CIRCUITS, AND CONTROLLERS 430.12 Motor Terminal Housings. Table 430.12(C)(1) and Table 430.12(C)(2) UL 778
  • 383.
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  • 386.
  • 388.
  • 389.
  • 390. Electrical Rigid Metal Conduit (RMC) Intermediate Metal Conduit (IMC) Electrical Metallic Tubing (EMT)  RMC is the heaviest-weight and thickest-wall steel conduit.  IMC has a thinner wall than RMC and weighs about one-third less than RMC.  EMT is the lightest-weight and thinnest-wall unthreaded steel conduit and also commonly called thin-wall conduit.
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  • 411. 14 Current-Carrying or Live Parts
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  • 452.
  • 453. You should know that!
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  • 482.
  • 483. 28 Polymeric Motor Supports
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