190513109009 Designing and Maintenance of Control

➢ We’ve created this guide to provide an overview of the key design considerations
applicable to industrial control panel design, including schematics, relevant
regulatory standards, and design considerations relating to every facet of
effective control panel design for industrial equipment and machinery.

➢ A variety of design considerations must be weighed throughout the design

process in order to design a control panel that meets functional requirements,
application specifications, and regulatory standards. The following design
decisions represent the primary design considerations in developing an industrial
control panel, although additional considerations specific to individual
applications may apply.

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190513109009 Designing and Maintenance of Control

Chapter 5

WIRING OF STAR-DELTA STARTER

2.1 Introduction of Star-Delta Starter

➢ A star delta starter is a type of reduced voltage starter. We use it to reduce the
starting current of the motor without using any external device or apparatus. This
is a big advantage of a star delta starter, as it typically has around 1/3 of the
inrush current compared to a DOL starter.

Fig. 4.1 Star delta starter

Fig. 4.2 Star connection

Fig. 4.3 Delta connection

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190513109009 Designing and Maintenance of Control

2.2 Why we use Star-Delta Starter?

➢ Most induction motors are started directly on line, but when very large motors
are started that way, they cause a disturbance of voltage on the supply lines
due to large starting current surges.

2.3 Working Principle of Star-Delta Starter

➢ This is the reduced voltage starting method. Voltage reduction during star-delta
starting is achieved by physically reconfiguring the motor windings as
illustrated in the figure below. During starting the motor windings are
connected in star configuration and this reduces the voltage across each
winding 3. This also reduces the torque by a factor of three.
➢ The Star/Delta starter is manufactured from three contactors, a timer and a
thermal overload. The contactors are smaller than the single contactor used in
a Direct on Line starter as they are controlling winding currents only. The

currents through the winding are 1/root 3 (58%) of the current in the line .

Fig. 4.4 Star Delta 2

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190513109009 Designing and Maintenance of Control

2.4 3 Phase VFD Diagram with Motor

FD wiring can be made in two ways:-

➢ Power wiring
➢ Control wiring

➢ Power wiring – Power wiring refers to the distribution of power. In the case of
VFD flow of power from VFD to the motor. As you know that we are making
the wiring of the 3 phase VFD and motor. Therefore 3 wires carry 3 phases i.e
(R, Y, & B) from the circuit breaker to the input terminal of the VFD and 3 wires
from VFD to the motor. This figure also helps you to understand the power
wiring of a VFD.

➢ Control wiring – control wiring is used for controlling purposes. They are used
to give commands to the control devices or communication between electrical
devices. In control wiring, there is no use of heavy voltage and therefore gauge
of wire is thinner. In control wiring normally standard 24vdc is used.

Fig 4.5 3 Phase VFD Wiring

Diagram

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190513109009 Designing and Maintenance of Control

➢ Various automation processes in the industry need control of AC induction

motors using AC drives. Presented here is a robust system for switching on/off,
varying the speed and direction of rotation of an industrial 3 Phase Induction
Motor using VFD and PLC. We use here Delta AC motor drive for its operation

➢ The first stage of a VFD is the converter, which comprises six diodes, which are
similar to check valves used in plumbing systems. These allow current to flow
in only one direction; the direction shown by the arrow in the diode symbol. For
example, whenever A-phase voltage (voltage is similar to pressure in plumbing
systems) is more positive than B- or C-phase voltages, that diode opens and
allows current to flow.

➢ When B phase becomes more positive than A phase, B-phase diode opens and
A-phase diode closes. The same is true for the three diodes on the negative side
of the bus. Thus, we get six current pulses as each diode opens and closes. This
is called a 6-pulse VFD, which is the standard configuration for current VFDs.

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190513109009 Designing and Maintenance of Control

Chapter 6

ROLES AND RESPONSIBILITIES DURING INTERNSHIP

4.1 DAILY TASK AND RESPONSIBILITIES

➢ My work in the company is Wiring of the Panel and Purchase Engineer.

➢ My work in the company is to ensure continuous Production and as a Production
Engineer.
➢ I must check every Panel Weekly that Panel is working normally or not.

➢ Servicing and replacing old or faulty equipment.

➢ Troubleshooting equipment malfunctions.
➢ If any Panel has defect or stop working, I must repair it and ensure continuous
production.
➢ Evaluating performance and providing feedback of workers.

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190513109009 Designing and Maintenance of Control

4.2 ROLES AND RESPONSIBILITIES

➢ I must monitor all the workers is doing their job properly.

➢ If any worker is not doing, it is work properly I must tell owner about that or
manage him by myself.
➢ I must build a healthy co-ordination between worker and owners.
➢ I must ensure continuous production and do maintenance when it is required.
➢ One of a supervisor’s most important responsibilities is managing a team.
➢ Evaluating performance and providing feedback of workers.
➢ Helping to resolve worker issues and disputes.

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