3 Month Internship Report

217815
Automation and Panel Manufacturing
AN INTERNSHIP REPORT
Submitted by
Savan Velajibhai Rathod
(180170124042)
In partial fulfillment for the award of the degree of
BACHELOR OF ENGINEERING
in
Power Electronics
Vishwakarma Government Engineering college
Chandkheda, Ahmedabad
Gujarat Technological University, Ahmedabad

[April - 2022]
Gujarat Technological University Vishwakarma Government Engineering College, Chandkheda

217815

Power Electronics
CERTIFICATE
This is to certify that the internship (3182401) report submitted along with
the internship Automation and Panel manufacturing has been carried by
Savan Velajibhai Rathod (180170124042) under my guidance in partial
fulfillment for the degree of Bachelor of Engineering in Power Electronics,
8th Semester of Gujarat Technological University, Ahmedabad during the

academic year 2021-22.
Guided by: -
Prof. Ashish P. Patel Dr. I. N. Trivedi

Assistant Professor (Head of the Department)
VGEC Chandkheda VGEC Chandkheda

217815

217815

Power Electronics
DECLARATION
We hereby declare that the Internship report submitted along with the
Internship entitled Automation and Panel manufacturing submitted in
partial fulfillment for the degree of Bachelor of Engineering in Power
Electronics to Gujarat Technological University, Ahmedabad, is a
bonafide record of original internship carried out by me at Akshar
Automation under the supervision of director Nilesh Vasani and that no
part of this report has been directly copied from any student’s reports or
taken from any other source, without providing due reference.
Name of the Student Sign of Student

217815
ACKNOWLEDGEMENT
At the onset, we would like to express our sincere gratitude to Akshar Automation for
their continuous support for our study and the related industrial training. We thank the staff
members of the organization for their insightful remarks and observations which incanted
us to broaden our knowledge. Their guidance and motivation made this training impactful
and an enriching learning experience. We express our heartfelt gratitude towards Mr.
Nilesh Vasani in helping me with the required inputs. We thank each and every person
who has been directly or indirectly involved in making the training truly successful.
We are also grateful to Vishwakarma Government Engineering College for providing us

with such a great opportunity to enhance our knowledge and widen our understanding and
expand our knowledge in the field of power engineering.
(180170124042)
Gujarat Technological University i|P a g e Vishwakarma Government Engineering College, Chandkheda

217815
ABSTRACT
For the deep understanding of the Industrial and engineering concepts,

practical training is important. Theoretical knowledge gives us the
fundamental concepts of engineering and practical training teaches us how
these concepts are used to capture today’s competitive market. Automation
greatly reduces the need for human sensory, human workforce and cost. With
the rapid growth in the sensors, control and automation technologies many
control systems such as PLC, SCADA are performing a significant role in the
automation of industries by using software and hardware tools. This paper
focuses on automation of an industrial system through a number of tools such
as PLC, Lab VIEW, and internet. The planned solution for industrial
automation is achieved by implementing a real-time controlling and
monitoring system. The design, construction, and operation of electrical
systems in educational facilities call for careful consideration of fire safety,
energy efficiency, and electrician safety. A conductor is the term for a material
that conducts electricity. Size and temperature determine the current-carrying
capacity of a conductor. Electrical control CAD is specialized software to
design circuit diagrams, cable production diagrams, and control panel layout
diagrams. Specialized electrical CAD previously existed, but CAD that unifies
management of design data have recently received a lot of attention
This report gives the complete idea of our work and what We learnt in Akshar
Automation for 12 weeks. It briefs about the various assignments given to me
and gain a better understanding of its basics.
Gujarat Technological University ii | P a g e Vishwakarma Government Engineering College, Chandkheda

217815
CONTENTS
ACKNOWLEDGEMENT .............................................................................................................. i
ABSTRACT .................................................................................................................................... ii
CONTENTS………………………………………………………………………………………iii
LIST OF FIGURS………………………………………………………………………………...v
ABBRIVIATION………………………………………………………………………………....vi
CHAPTER 1: Introduction ........................................................................................................... 1
1.1 About Company .................................................................................................................. 1
1.1.1 Company Origin ......................................................................................................... 1
1.1.2 Mission ................................................................................................................. 1
1.2 Products .................................................................................................................................. 1
1.2.1 Power Control Center (PCC) Panel ............................................................................ 2
1.2.2 Motor Control Center (MCC) Panel ........................................................................... 2
1.2.3 Low Tension Panel ..................................................................................................... 3
1.2.4 VFD Control Panel ..................................................................................................... 3
1.3 Industry………………………………………………………………………………………4
CHAPTER 2 : Control Panels ....................................................................................................... 5
2.1 Power Control Center (PCC) Panel ........................................................................................ 5
2.2 Motor Control Center (MCC) Panel ....................................................................................... 7
2.3 Fire Hydrant Control Panel .................................................................................................... 8
2.3.1 Construction ............................................................................................................... 8
Chapter 3 : VARIABLE FREQUENCY DRIVE ...................................................................... 10
3.1 Variable Frequency drive ..................................................................................................... 10
3.2 VFD Control Panel ............................................................................................................... 11
3.2.1 Use Of VFD Panels ........................................................................................... 11
Chapter 4 ; Panel Component ..................................................................................................... 13
4.1 Contactor .............................................................................................................................. 13
4.1.1 Introduction .............................................................................................................. 13
4.1.2 Construction ............................................................................................................. 13
4.1.3 Operation And Working: .......................................................................................... 14
4.1.4 Types of Contactors There Are Basically Two Types Of Contactors: ..................... 15
4.1.5 Power Contactors ..................................................................................................... 15
4.1.6 Control Contactors.................................................................................................... 15
4.1.7 Applications.............................................................................................................. 16
4.2 Star-Delta Starter .................................................................................................................. 17
4.2.1 Introduction .............................................................................................................. 17
4.2.2 Principle And Working............................................................................................. 17
4.2.3 Star Delta Starter Units............................................................................................. 19
Gujarat Technological University iii | P a g e Vishwakarma Government Engineering College, Chandkheda

217815
4.2.4 Power Circuit Diagram Of Star-Delta Starter........................................................... 19

4.2.5 Control Diagram Of Star-Delta Starter..................................................................... 20
4.2.6 Advantages of Star-Delta Starter .............................................................................. 22
4.2.7 Disadvantages of Star-Delta Starter ......................................................................... 22
4.2.8 Applications of Star-Delta Starter ............................................................................ 23
4.3 DOL (Direct Online Starter) ................................................................................................. 23
4.3.1 Introduction .............................................................................................................. 23
4.3.2 Principle And Working Of Direct On Line Starter (DOL) ....................................... 23
4.3.3 Advantages Of DOL Starter ..................................................................................... 24
4.3.4 Disadvantages of DOL Starter.................................................................................. 24
4.3.5 Features of DOL Starter ........................................................................................... 24
4.3.6 Applications.............................................................................................................. 25
4.4 RDOL (Reverse Direct Online Starter) ................................................................................ 25
4.4.1 Introduction .............................................................................................................. 25
4.4.2 Principle and Working .............................................................................................. 25
Chapter 5 : Conclusion ............................................................................................................... 27
Reference ................................................................................................................. 28
Gujarat Technological University iv | P a g e Vishwakarma Government Engineering College, Chandkheda

217815
LIST OF FIGURES
Figure 1 : PCC PANEL .................................................................................................................... 2

Figure 2: MCC PANEL ................................................................................................................... 2
Figure 3 : LT PANEL ....................................................................................................................... 3
Figure 4 :VFD control panel............................................................................................................. 3
Figure 5 : PCC Panel ........................................................................................................................ 6
Figure 6: MCC Panel ........................................................................................................................ 8
Figure 7 : FIRE HYDRANT PANEL.............................................................................................. 8
Figure 8: Variable Frequency Drive ............................................................................................... 10
Figure 9 VFD Block Diagram ........................................................................................................ 10
Figure 10: VFD CONTROL PANEL ............................................................................................. 11
Figure 11: CONTACTOR .............................................................................................................. 13
Figure 12 :BLOCK DIAGRAM OF CONTROL CONTACTOR .................................................. 16
Figure 13: STAR-DELTA STARTER ........................................................................................... 18
Figure 14: CIRCUIT DIAGRAM OF STAR-DELTACONTACTOR .......................................... 20
Figure 15 : CONTROL DIAGRAM OF STAR-DELTA CONTACTOR ...................................... 22
Figure 16: RDOL............................................................................................................................ 25
Figure 17 : RDOL CONTROL CIRCUIT ...................................................................................... 26
Gujarat Technological University v|P ag e Vishwakarma Government Engineering College, Chandkheda

217815
ABBREVIATION
MVD Medium Voltage Drive
PCC Power Control Center
MCC Motor Control Center
LT Low Tension
VFD Variable Frequency Drive
FHC Fire Hydrant Control
DOL Direct Online Starter
RDOL Reverse Direct Online Starter
NO Normally Open
NC Normally Close
R,Y,B Colour Code of Wire
KW Kilo Watt
DG Direct General
Gujarat Technological University vi | P a g e Vishwakarma Government Engineering College, Chandkheda

217815 Introduction
CHAPTER 1 : Introduction
1.1 About Company
With an eye on the future, Akshar Automation has established a farsighted corporate
identity. The company wants to meet future expectations of customers in the field of Motor
Control, Automation and Industrial Automation with further advancement offering leading
technologies on a national platform.
Today, Akshar Automation, a leading manufacture to different types of panels such as

power panel and control panel. In addition, motor control products like AC Drives, High
Frequency Drives, Medium Voltage Drives (MVD), Industrial Control Panels and Power
Electronics products like AC Power Controller / Heater controller, Power Converters and
Customized Power Supplies.
1.1.1 Company Origin

Akshar Automation was established in 2010 at Ahmedabad (Gujarat, India)
1.1.2 Mission
To provide best Quality, Highly Reliable, Human Friendly, Highly Safe & Cost Effective
solutions and services as per customers applications & requirements. To achieve success
through the commitment of our employees and actively engage, empower and continuously
develop our workforce.
1.2 Products
At Akshar Automation there are four main product types which are shown below.
• Power Control Center (PCC) Panel

• Motor Control Center (MCC) Panel
• Low tension panel
• VFD control panel
• Breaking panel
• Heating pane
Gujarat Technological University 1|P ag e Vishwakarma Government Engineering College, Chandkheda

217815 Introduction
1.2.1 Power Control Center (PCC) Panel
PCC Panels are the most essential part of electrical system of an industry from where the
power of the industry is controlled. PCC Panel is a power distribution board to control the
Electrical power supplied to HT Panels, MCC panels and transformers who play vital role
in all electrical control system.
Figure 1 : PCC PANEL
[1]
1.2.2 Motor Control Center (MCC) Panel
The Motor Control Center are used in industrial and commercial applications for
connecting the individual motors for manually, remotely or automatically starting, stopping
selecting forward and reverse rotation, selecting and regulating the speed, regulating and
limiting the torque and protecting against overload, single phasing, phase imbalance, earth
fault, under current, under / over voltage, lock rotor current, high winding temperature etc.
Figure 2: MCC PANEL[2]

217815 Introduction
1.2.3 Low Tension Panel
There are various uses of LT Control Panel as per the user requirement, the main being as
Control Center or Feeder or Distribution Board.LT Power Panel receives the main power
supply Either from Generator or Transformer and distributes the same to various electrical
devices and distribution boards.
Figure 3 : LT PANEL[3]
1.2.4 VFD Control Panel
Electrical VFD control panels are designed to control the speed of electric motor and feed
pump. They are widely used in drilling, pumping and other large machine applications. The
VFD panels are widely used in tube mills, paper mills, extruder plants, rolling Mills, cable
industry and CTL Lines. They are even installed in hospitals, business houses and other
public places. VFD control panel are designed to match variable speed requirements of a
process unit and so are vigorously tested on various speed parameters.
Figure 4 :VFD control panel

217815 Introduction
1.3 Application Area

Akshar Automation have main industrial business verticals like
● Pharmaceutical industries
● Agriculture industries
● Mechanical industries
● Power substation

217815 Control Panels
CHAPTER 2 : Control Panels
Akshar Automation is the leading electrical control panel manufacturer also provide
abbreviation Panel in Ahmedabad. electrical control panel is a combination of Multiple
electrical devices which use electrical power to control the various mechanical functions of
industrial equipment or machinery. We believe that our electrical control panel quality and
efficient After Sale Service system is enhanced by developing deep and transparent
relationship with our esteemed clients.
A company Next-Gen Power Controls has been widely acclaimed as one of the most
reliable manufacturing, supplying, as well as distributing firm of Abbreviation Panel in the
whole market arena. Our customers have appreciated us for providing them with a highly
accurate and qualitative range of Electrical Panels and other services. This are inclined to
provide our clients with the option of customization as per their specifications.
Types of Control Panel
1. PCC panel
2. MCC panel
3. LT panel
4. FHC panel
5. VFD based control panel
2.1 Power Control Center (PCC) Panel
Electrical Power Control Center Panel (PCC Panel) are modular structured electrical
control panel used to control power supply in large industrial as well as commercial units.
Power supplied to big and heavy machineries, equipment, motors and transformers are
controlled as per the requirement. Main LT Panel / PCC Panel with single / multiple
Incomers, Bus coupler with Electrical and/or mechanical interlocking are provided.
Protective Relays, Indication lamp, Meters are to be provided whichever required.
PCC Panel are offered with various Design like Top / Middle / Horizontal Bus bar
chambers, Panel with Aluminum or Copper Bus bar, Top / Bottom / Front / Rear cable
Termination Combination of APFC part with the Panel. Facilities like DG Incomer with
AMF function, Cut-off of non-essential feeder at the event of Mains supply. PCC Panel
Gujarat Technological University 5|P a g e Vishwakarma Government Engineering College, Chandkheda

with provision to connect bus duct at main Incomer side.
Figure 5 : PCC PANEL

➢ Construction Details
• Modular / Non- compartmentalized construction.

• Panel structure with MS CRCA/SS.
• Indoor / Outdoor type Structure.
• Single front/double front Operated.
• Provision for Extensible for future use.
• Provision of Rubber Gaskets.
• Arrangement for heat dissipation by means of Exhaust Fan or Lowers.
➢ Pre-Treatment & Painting
• Three Tank / Seven Tank Pretreatment process

• Final paint shade as per IS or client specifications
• Synthetic Enamel / Epoxy based primer / Powder coating as per customer’s requirement
➢ Bus Bar Arrangement & Cable Alley
• Electrical Grade Aluminum / Copper Busbar

• Main busbar chamber at top / bottom of the Panel
• Separate chamber for vertical dropper
• Busbar supports of SMC/DMC Material
• Busbar System design on basis of continuous Current rating and Fault level with stand
capacity
• Allowable temperature rise as per IS 8623 or as per specifications

• Top / Bottom cable entry. Detachable gland plate for cable entry. [4]
➢ Assembly & Wiring
• Selection of components from Approved / Reputed vendor list as per Approved

Drawing
• Design of Internal Layout of optimum usage of space
• Internal wiring with 660/1100 v Grade PVC coated stranded Copper Flexible Wires
• Crimping Lugs are used for internal Connections / Terminations
• Quality Assurance & Control Systems
• Inspection of Fabrication structure for dimension as per approved G.A. drawing
• Inspection of Painting / Powder coating
➢ Quality Assurance & Control Systems

• Inspection of Fabrication structure for dimension as per approved G.A. drawing
• Inspection of Painting / Powder coating
2.2 Motor Control Center (MCC) Panel
The motor control center (MCC Panel) is the focal area for controlling electric motors.
Which has a motor starter, wire, or electrical switch and is forcibly separated. A unique
instrument called a motor control board is utilized to control motors in many ventures in
numerous business and Industry applications different electric motors are required and it is
normal alluring to control a portion of the motors.
MCC Panel are with Fix / Draw Out type. MCC Panel with DOL, STAR-DELTA, RDOL,
starters. MCC Panel are with various design like Single / Double Front, with DCS /
Marshaling terminations. Facilities of different control voltage with control transformer
control Bus With type-2 co-ordination wherever required.

Figure 6: MCC PANEL
2.3 Fire Hydrant Control Panel
This Panel with DOL, STAR-DELTA, VFD starters. Provision of Main Pump, Jockey
Pump, Sprinkler Pump, Booster Pump, Engine Driven Pump. Automation with Pressure
switch. Facilities of different control voltage with control transformer control Bus. With
type-2 co-ordination wherever required.
Figure 7 : FIRE HYDRANT PANEL[5]
2.3.1 Construction
In areas subject to freezing temperatures, at most only a portion of the hydrant is above
ground. The valve is located below the frost line and connected by a riser to the above-

ground portion. A valve rod extends from the valve up through a seal at the top of the
hydrant, where it can be operated with the proper wrench. This design is known as a "dry
barrel" hydrant, in that the barrel, or vertical body of the hydrant, is normally dry. A drain
valve underground opens when the water valve is completely closed; this allows all water
to drain from the hydrant body to prevent the hydrant from freezing.
In warm areas, above-ground hydrants may be used with one or more valves in the above-
ground portion. Unlike with cold-weather hydrants, it is possible to turn the water supply
on and off to each port. This style is known as a "wet barrel" hydrant.

217815 Variable Frequency Drive
Chapter 3 : VARIABLE FREQUENCY DRIVE
3.1 Variable Frequency drive
Figure 8: VARIABLE FREQUENCY DRIVE
Figure 9 VFD BLOCK DIAGRAM
Variable frequency drive is used for motor control. It controls the speed of motor by
varying V/F ration. In starting frequency is low and step by step increased and speed of
motor increases. To boost torque, we increase voltage and increases V/F ratio. But by
increasing higher V/F ratio motor gets saturated.
There is rectifier unit which converts 3 Phase AC Supply into DC Supply. Now this DC
Supply is filtered by DC CHOKE. Diodes are used for ratification. Now rectified DC is not
a pure DC so we need filter DC and make it pure DC Supply. With the help of Capacitor
and Choke DC Supply is filtered and make pure DC.
With the help of high IGBT DC Supply is converted into AC Supply. IGBT is used because
Gujarat Technological University 10 | P a g e Vishwakarma Government Engineering College, Chandkheda

of it has high switching speed. With the help of SMPS VFD is driven. In the control card
of VFD all the Digital Input and Output and also Analogue Input and Outputs are connected
also with communication devices are connected in the control card of the VFD. According
to connection programming is to be done in control cad of VFD.
With the help of high IGBT DC Supply is converted into AC Supply. IGBT is used because
of it has high switching speed. With the help of SMPS VFD is driven. In the control card
of VFD all the Digital Input and Output and also Analogue Input and Outputs are connected
also with communication devices are connected in the control card of the VFD. According
to connection programming is to be done in control cad of VFD.
3.2 VFD Control Panel
Variable speed drive is a dedicated component of the electrical control panel, the panel's
frequency convention and main features are depending on the inner VFD and other
components configuration. VFD panels are different according to their different functions
and applications, generally, it needs customized manufacture base on specified running
environment, like in constant water supply panels (one panel control 1, 2, 3 pumps, etc.),
escalators control panels, central air condition circulating pump panels, and fan's control
panels.
Figure 10: VFD CONTROL PANEL
3.2.1 Use Of VFD Panels
1. Power switching and protection
VFD panels are designed with a circuit breaker usually, which are connected to the input
line power supply to switch the panel on/off, and provide protection when short circuit
oroverload occurs in the circuits and variable speed drives. In addition, VFD panels can
disconnect power to ensure operator's safety during motor maintenance.

2. Adjustable Speed
A frequency control potentiometer is installed on the VFD panel's door, to transmit

command signals to the motor according to operator assigned. VFD panel has mains
switching function to ensure the system continues operation in case of the variable
frequency drive failed.
3. Visual Control
VFD panel has display and operation panel on the front body, which is connected to the
electrical components inside the control cabinet. It can display the panel's operational status
visually, and convenient for operator control the motor in actual field operations.
Manufacturers also equip with a variety of instruments and indicators inside the variable
frequency drive panels, such as voltmeter, ammeter, frequency meter, and power
indicator light, alarm lights, running lights, power frequency lights etc, which will
monitor the VFD control panels working status in real time.
4. Security Protection
Include variable frequency drive, all other electrical components are integrated inside the
VFD panel, thus reducing the impact of external environment to the electrical components,
and ensure the operator safety level like reducing shock hazard rate, so it has a better safety
protection.
5. Typical Applications
water supply, air compressors, central air conditioning, port machinery, machine tools,
boilers, paper machinery, food machinery and so on.
Gujarat Technological University 12 | P a g e Vishwakarma Government Engineering College,Chandkheda

217815 Panel Components
Chapter 4 : Panel Component
4.1 Contactor
4.1.1 Introduction
A contactor is an electrically controlled switch used for switching a power circuit, similar to a
relay except with higher current ratings. A contactor is controlled by a circuit which has a
much lower power level than the switched circuit. Contactors typically have multiple contacts,
and those contacts are usually (but not always) normally-open, so that power to the load is shut
off when the coil is de-energized.
Figure 11: CONTACTOR
Contactors come in many forms with varying capacities and features. The basic work of a
contactor is to interrupt a short circuit current. So they can use as circuit breakers. Contactors
range from those having a breaking current of several amperes to thousands of amperes and
24 V DC to many kilovolts. The physical size of contactors ranges from a device small enough
to pick up with one hand, to large devices approximately a meter (yard) on a side. Contactors
are used to control electric motors, lighting, heating, capacitor banks, thermal evaporators, and
other electrical loads.
4.1.2 Construction
A contactor has five components

1. Contacts
2. Electromagnet (or coil)
3. Enclosure
4. Magnetic blowouts

5. Economizer circuit
1) The Contacts: Are the current carrying part of the contactor. This includes power
contacts, auxiliary contacts, and contact springs. The power contacts carry high current and
auxiliary contacts receives signal to make the contactor open or close or send the status of the
contactor (on or off) to external systems. The contact springs provide mechanical force to make
the contact on or off.
2) The Electromagnet (or coil): Provides the driving force to close the contacts. It
contains a metallic moving core made of iron alloy which situated over the magnetic coil.
When circuit is closed, it forced to connect with magnetic coil due to magnetic property.
3) The Enclosure: Is a frame housing the contact and the electromagnet. Enclosures are
made of insulating materials like Bakelite, Nylon 6, and thermosetting plastics to protect and
insulate the contacts and to provide some measure of protection against personnel touching the
contacts.
4) Magnetic Blowouts: use blowout coils to lengthen and move the electric arc. These are
especially useful in DC power circuits. AC arcs have periods of low current, during which the
arc can be extinguished with relative ease, but DC arcs have continuous high current, so
blowing them out requires the arc to be stretched further than an AC arc of the same current.
5) Economizer Circuit: It is installed to reduce the power required to keep a contactor

closed; an auxiliary contact reduces coil current after the contactor closes. A somewhat greater
amount of power is required to initially close a contactor than is required to keep it closed.
Such a circuit can save a substantial amount of power and allow the energized coil to stay
cooler. Economizer circuits are nearly always applied on direct-current contactor coils and on
large alternating current contactor coils.[6]
4.1.3 Operation and Working:
The basic difference between a relay and a contactor is current carrying capacity. Relays tend
to be of lower capacity and are usually designed for both normally closed and normally open
applications. Devices switching more than 15 amperes or in circuits rated more than a few
kilowatts are usually called contactors.
When current passes through the electromagnet, a magnetic field is produced, which attracts
the moving core of the contactor. The electromagnet coil draws more current initially, until its
inductance increases when the metal core enters the coil. The moving contact is propelled by

the moving core; the force developed by the electromagnet holds the moving and fixed contacts
together. When the contactor coil is de-energized, gravity or a spring returns the electromagnet
core to its initial position and opens the contacts.
For contactors energized with alternating current, a small part of the core is surrounded with a
shading coil, which slightly delays the magnetic flux in the core. The effect is to average out
the alternating pull of the magnetic field and so prevent the core from buzzing at twice line
frequency.
4.1.4 Types of Contactors There are Basically Two Types Of Contactors:
• Power contactors
• Control contactors
4.1.5 Power Contactors
Power contactors are used to control high power devices. They are basically use for controlling
of electric motors. It contains of three terminals on both input and output sides, called L1, L2
&L3 and T1, T2 & T3. They are used for providing 3-phase supply to contactor depend upon
the ratings.
4.1.6 Control Contactors
Control contactors are basically used as magnetic switches. They use in low power
applications. It contains several normally-opened (NO) and normally-closed (NC) terminals
which use as controlling switches of contactor. The main property of contactor is that its
terminal works either as NO or NC at a time. This property is used to inter lock two or more
contactors used in various applications.

Figure 12 :BLOCK DIAGRAM OF CONTROL CONTACTOR
4.1.7 Applications
The basic application of contactors is to develop the control logic for requirement of electric
motors of different power ratings in industries for different tasks. Contactors are also using as
circuit breakers in some applications.it is also used as circuit protection for electrical.
1. Lighting control
To reduce power consumption in the contactor coils, latching contactors are used, which have
two operating coils. One coil, momentarily energized, closes the power circuit contacts, which
are then mechanically held closed, the second coil opens the contacts.
2. Safety purpose
Long life to motor then contractor are used. To any fault any damage to save to use
contactor.
3. Magnetic starter
A magnetic starter is a device designed to provide power to electric motors. It includes a
contactor as an essential component, while also providing power-cutoff, under-voltage, and
overload protection.

4. Vacuum contactor
Vacuum contactors utilize vacuum bottle encapsulated contacts to suppress the arc. This arc
suppression allows the contacts to be much smaller and use less space than air break contacts
at higher currents. As the contacts are encapsulated, vacuum contactors are used fairly
extensively in dirty applications, such as mining.
4.2 Star-Delta Starter
4.2.1 Introduction
“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. To limit the starting current surge, large induction motors are started at
reduced voltage and then have full supply voltage reconnected when they run up to near
rotated speed. Two methods are used for reduction of starting voltage are star delta starting
and auto transformer stating.”
4.2.2 Principle And Working
When be motor is stat then is initially torque and current is very high mean When motor is
start then motor is taking double current in its rating, so in initially condition motor in high
current then we, we are use 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. After a
period of time the winding are reconfigured as delta and the motor runs normally.

Figure 13: STAR-DELTA STARTER
In star connection the current is same but the voltage is different.

Phase current = line current
Phase voltage = 1.73 line voltage
In delta connection the current is different but the voltage is same.

Phase voltage = phase voltage
Phase current = 1.73 line current
Star/Delta starters are probably the most common reduced voltage starters. They are used
in an attempt to reduce the start current applied to the motor during start as a means of
reducing the disturbances and interference on the electrical supply.
Traditionally in many supply regions, there has been a requirement to fit a reduced voltage
starter on all motors greater than 5HP (4KW). The Star/Delta (or Wye/Delta) starter is one
of the lowest cost electromechanical reduced voltage starters that can be applied.
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.

There are two contactors that are close during run, often referred to as the main contractor
and the delta contactor. These are AC3 rated at 58% of the current rating of the motor. The
third contactor is the star contactor and that only carries star current while the motor is
connected in star. The current in star is one third of the current in delta, so this contactor
can be AC3 rated at one third (33%) of the motor rating.
4.2.3 Star Delta Starter Units
• Contactor
• Time relay
4.2.4 Power Circuit Diagram Of Star-Delta Starter
The main circuit breaker serves as the main power supply switch that supplies electricity
to the power circuit.
The main contactor connects the reference source voltage R, Y, B to the primary terminal
of the motor U1, V1, and W1.
In operation, the Main Contactor (KM3) and the Star Contactor (KM1) are closed initially,
and then after a period of time, the star contactor is opened, and then the delta contactor
(KM2) is closed. The control of the contactors is by the timer (K1T) built into the starter.
The Star and Delta are electrically interlocked and preferably mechanically interlocked as
well. In effect, there are four states.
The star contactor serves to initially short the secondary terminal of the motor U2, V2, and
W2 for the start sequence during the initial run of the motor from standstill. This provides
one third of DOL current to the motor, thus reducing the high inrush current inherent with
large capacity motors at startup. Controlling the interchanging star connection and delta
connection of an AC induction motor is achieved by means of a star delta or wye delta
control circuit. The control circuit consists of push button switches, auxiliary contacts and
a timer.

Figure 14: CIRCUIT DIAGRAM OF STAR-DELTACONTACTOR
4.2.5 Control Diagram of Star-Delta Starter
The ON push button starts the circuit by initially energizing Star Contactor Coil (KM1) of
star circuit and Timer Coil (KT) circuit.
When Star Contactor Coil (KM1) energized, Star Main and Auxiliary contactor change its
position from NO to NC.
When Star Auxiliary Contactor (1) (which is placed on Main Contactor coil circuit)
became NO to NC it’s complete The Circuit of Main contactor Coil (KM3) so Main
Contactor Coil energized and Main Contactor’s Main and Auxiliary Contactor Change its
Position from NO To NC. This sequence happens in a friction of time. After pushing the
ON push button switch, the auxiliary contact of the main contactor coil
(2) which is connected in parallel across the ON push button will become NO to NC,
thereby providing a latch to hold the main contactor coil activated which eventually
maintains the control circuit active even after releasing the ON push button switch.

When Star Main Contactor (KM1) close its connect Motor connects on STAR and it’s
connected in STAR until Time Delay Auxiliary contact KT (3) become NC to NO. Once
the time delay is reached its specified Time, the timer’s auxiliary contacts (KT)
(3) in Star Coil circuit will change its position from NC to NO and at the Same Time
auxiliary contactor (KT) in Delta Coil Circuit
(4) change its Position from NO to NC so Delta coil energized and Delta Main Contactor
becomes NO to NC. Now Motor terminal connection change from star to delta connection.
A normally close auxiliary contact from both star and delta contactors
(5&6)are also placed opposite of both star and delta contactor coils, these interlock contacts
serves as safety switches to prevent simultaneous activation of both star and delta contactor
coils, so that one cannot be activated without the other deactivated first.
Thus, the delta contactor coil cannot be active when the star contactor coil is active, and
similarly, the star contactor coil cannot also be active while the delta contactor coil is
active. The control circuit above also provides two interrupting contacts to shut down the
motor. The OFF push button switch break the control circuit and the motor when necessary.
The thermal overload contact is a protective device which automatically opens the STOP
Control circuit in case when motor overload current is detected by the thermal
overload relay, this is to prevent burning of the motor in case of excessive load beyond the
rated capacity of the motor is detected by the thermal overload relay.
At some point during starting it is necessary to change from a star connected winding to a
delta connected winding. Power and control circuits can be arranged to this in one of two
ways – open transition or closed transition.

Figure 15 : CONTROL DIAGRAM OF STAR-DELTA CONTACTOR
4.2.6 Advantages of Star-Delta Starter
1. The operation of the star-delta method is simple and rugged.

2. It is relatively cheap compared to other reduced voltage methods.
3. Good Torque/Current Performance.
4. It draws 2 times starting current of the full load ampere of the motor connected.
4.2.7 Disadvantages of Star-Delta Starter
1. Low Starting Torque.

2. Sometime break In Supply.
3. Six Terminal Motor Required only connected in delta starter.
4. It provides only 33% starting torque.
5. In this method of starting initially motor is connected in star and then after change over
the motor is connected in delta. The delta of motor is formed in starter and not on motor
terminals.
6. Applications with a load torque higher than 50 % of the motor rated torque will not be
able to start using the start-delta starter.

4.2.8 Applications of Star-Delta Starter
1. The star-delta method is usually only applied to low to medium voltage and light starting
Torque motors.
2. The received starting current is about 30 % of the starting current during direct on line
start and the starting torque is reduced to about 25 % of the torque available at a D.O.L
start. This starting method only works when the application is light loaded during the start.
If the motor is too heavily loaded, there will not be enough torque to accelerate the motor
up to speed before switching over to the delta position.
4.3 DOL (Direct Online Starter)
4.3.1 Introduction
The simplest form of motor starter for the induction motor is the Direct on Line starter.
The Direct on Line Motor Starter (DOL) consist a MCCB or Circuit Breaker, Contactor
and an overload relay for protection. Electromagnetic contactor which can be opened by
the thermal overload relay under fault conditions. Typically, the contactor will be
controlled by separate start and stop buttons, and an auxiliary contact on the contactor is
used, across the start button, as a hold in contact. The contactor is electrically latched
closed while the motor is operating.
4.3.2 Principle and Working Of Direct On Line Starter (DOL)
To start, the contactor is closed, applying full line voltage to the motor windings. The
motor will draw a very high inrush current for a very short time, the magnetic field in the
iron, and then the current will be limited to the Locked Rotor Current of the motor. The
motor will develop Locked Rotor Torque and begin to accelerate towards full speed.
As the motor accelerates, the current will begin to drop, but will not drop significantly until
the motor is at a high speed, typically about 85% of synchronous speed. The actual starting
current curve is a function of the motor design, and the terminal voltage, and is totally
independent of the motor load.
The motor load will affect the time taken for the motor to accelerate to full speed and
therefore the duration of the high starting current, but not the magnitude of the starting
current. Provided the torque developed by the motor exceeds the load torque at all speeds
during the start cycle, the motor will reach full speed. If the torque delivered by the motor
is less than the torque of the load at any speed during the start cycle, the motor will stops
accelerating. If the starting torque with a DOL starter is insufficient for the load, the motor

must be replaced with a motor which can develop a higher starting torque.
The acceleration torque is the torque developed by the motor minus the load torque, and
will change as the motor accelerates due to the motor speed torque curve and the load speed
torque curve. The start time is dependent on the acceleration torque and the load inertia.
This may cause an electrical problem with the supply, or it may cause a mechanical
problem with the driven load. So this will be inconvenient for the users of the supply line,
always experience a voltage drop when starting a motor. But if this motor is not a high
power one it does not affect much.
4.3.3 Advantages Of DOL Starter
1. Most Economical and Cheapest Starter.

2. Simple to establish, operate and maintain.
3. Simple Control Circuitry.
4. Easy to understand and trouble‐shoot.
5. It provides 100% torque at the time of starting.
6. Only one set of cable is required from starter to motor.
7. Motor is connected in delta at motor terminals.
4.3.4 Disadvantages of DOL Starter
1. It does not reduce the starting current of the motor.

2. High Starting Current: Very High Starting Current (Typically 6 to 8 times the FLC of
the motor).
3. Mechanically Harsh: Thermal Stress on the motor, thereby reducing its life.
4. Voltage Dip: There is a big voltage dip in the electrical installation because of high in-
rush current affecting other customers connected to the same lines and therefore not
suitable for higher size squirrel cage motors
5. High starting Torque: Unnecessary high starting torque, even when not required by the
load, thereby increased mechanical stress on the mechanical systems such as rotor shaft,
bearings, gearbox, coupling, chain drive, connected equipment’s, etc. leading to
premature failure and plant down times.
4.3.5 Features of DOL Starter
1. For low- and medium-power three-phase motors.

2. Three connection lines (circuit layout: star or delta).
3. High starting torque.
4. Very high mechanical load.
5. High current peaks.
6. Voltage dips.

7. Simple switching devices.
4.3.6 Applications
1. A direct on line starter can be used if the high inrush current of the motor does not
cause.
2. Excessive voltage drop in the supply circuit. The maximum size of a motor allowed on
a direct on
3. Line starter may be limited by the supply utility for this reason. For example, a utility
may require
4. Rural customers to use reduced-voltage starters for motors larger than 10 kW
4.4 RDOL (Reverse Direct Online Starter)
4.4.1 Introduction
“RDOL [Reversible DOL] starters are simply two DOL starters in the same box and allow
the motor to be started in one direction then in the other direction”.
4.4.2 Principle and Working
RDOL made to two DOL circuit in series, both terminal of A2 are shorted to each other and
that point it’s called natural. Do the interlocking between both DOL circuits. Interlocking are
very important to both DOL circuit because if you are worked in at a time only one contactor
then will we use interlocking. RDOL circuit are also used to run motor in forward and reverse
direction.
Figure 16: RDOL

RDOL [Reversible DOL] starters are simply two DOL starters in the same box and allow the
motor to be started in one direction and then in the other direction. Assume that we are talking
about three phase motors. Suppose a sheet-metal goods factory uses a 10 kW motor to drive a
set of rollers. When sheet metal goods are being made, it is sometimes necessary to roll the
sheet metal in one direction and then the other.
Figure 17 : RDOL CONTROL CIRCUIT
Above diagram is shown as in output three terminal are here that terminal are used to connect
to motor (U V W). P1 and P2 are two contactor are connected that is power contactor. When
supply is on then contactor is hold, now if P1 contactor is on then motor is run in forward
direction and when the contactor P2 is hold then the motor is run in reverse direction. Both
contactor is working same but only difference is that P1 is connected to direct connected mean
R to R, Y to Y and B to B, then motor is run in forward direction but in P2 contactor in phase
are change to each other mean R to R, Y to B and B to Y then the motor is reverse direction.
Now that circuit is very simple and run to motor reverse and forward very simply.

217815 Conclusion
Chapter 5 : Conclusion & Discussion
There are multifarious abilities and skills which I have developed in my professional life.
Overall, I would like to apprised that firstly, I have learnt about basic knowledge of
electrical equipment or component which used in panel manufacturing. secondly, I had
been learnt about concept and working of those components and getting knowledge about
how to manufacturing various types of panels. On the continuous evaluation, 23 February
2022, I have been gone to INTAS PHARMACUETICAL PVT.LTD for installment of
fluidized bed dryer (FBD) and rapid mixer granulator (RMG) machines. Secondly, I had
been gone to CONSOLE ENERGY IN ZAKH GIDC at Vehlal gam for installment of solar
panel laminating machine. There were multicuisine problem which faced by me. For
instance, once upon time, I have faced a CNC machine which display is hitting and not
working properly as well as I spent to much time on it and after that I have founded a one
solution like we will putting a small exhaust fan behind display. In a nutshell, we solved
that problem and saved 40 thousand rupees of the clint’s organization. Thus, I would like
to talk about safety which I have learnt from it. For illustration, When, we worked with
grinding machine for cutting bus bar of the panel then, we have weared a safety glasses as
well as connect a safety disc with grinding machine. When I visited a company first time
that I don’t know about anything including a basic concept of basic components which used
in manufacturing of panel. So I learnt from this is when any student will go for the
internship in any company. Students are knowing basic concept of all components which
used in that particular field.

217815 Reference
Reference
1. https://tinyurl.com/59hea9ss
2. https://www.indiamart.com/proddetail/mcc-panel-14670301988.html
3. https://www.indiamart.com/proddetail/lt-panels-20429389497.html
4. Electrical Control Panel Manufacturer - Nextgen power controls (nextgenpanels.com)
5. https://tinyurl.com/2dpbekz5
6. https://www.slideshare.net/AshishPatidar4/training-report-50397904
7. https://www.aksharautomation.co.in/
8. https://www.indiamart.com/aksharautomation/about-us.html
9. https://www.mavenautomation.com/lt-panel.html
10. https://nextgenpanels.com/our-products.php

3 Month Internship Report

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

3 Month Internship Report

Uploaded by

Copyright:

Available Formats

217815

Automation and Panel Manufacturing

Savan Velajibhai Rathod

In partial fulfillment for the award of the degree of

Gujarat Technological University, Ahmedabad

Gujarat Technological University Vishwakarma Government Engineering College, Chandkheda

Vishwakarma Government Engineering college

8th Semester of Gujarat Technological University, Ahmedabad during the

Prof. Ashish P. Patel Dr. I. N. Trivedi

Gujarat Technological University Vishwakarma Government Engineering College, Chandkheda

Gujarat Technological University Vishwakarma Government Engineering College, Chandkheda

Vishwakarma Government Engineering college

Name of the Student Sign of Student

Savan Velajibhai Rathod

Gujarat Technological University Vishwakarma Government Engineering College, Chandkheda

We are also grateful to Vishwakarma Government Engineering College for providing us

Savan Velajibhai Rathod

Gujarat Technological University i|P a g e Vishwakarma Government Engineering College, Chandkheda

For the deep understanding of the Industrial and engineering concepts,

Gujarat Technological University ii | P a g e Vishwakarma Government Engineering College, Chandkheda

Gujarat Technological University iii | P a g e Vishwakarma Government Engineering College, Chandkheda

4.2.4 Power Circuit Diagram Of Star-Delta Starter........................................................... 19

Gujarat Technological University iv | P a g e Vishwakarma Government Engineering College, Chandkheda

Figure 1 : PCC PANEL .................................................................................................................... 2

Gujarat Technological University v|P ag e Vishwakarma Government Engineering College, Chandkheda

MVD Medium Voltage Drive

PCC Power Control Center

MCC Motor Control Center

VFD Variable Frequency Drive

FHC Fire Hydrant Control

DOL Direct Online Starter

RDOL Reverse Direct Online Starter

R,Y,B Colour Code of Wire

Gujarat Technological University vi | P a g e Vishwakarma Government Engineering College, Chandkheda

1.1 About Company

Today, Akshar Automation, a leading manufacture to different types of panels such as

1.1.1 Company Origin

• Power Control Center (PCC) Panel

Gujarat Technological University 1|P ag e Vishwakarma Government Engineering College, Chandkheda

1.2.1 Power Control Center (PCC) Panel

Figure 1 : PCC PANEL

1.2.2 Motor Control Center (MCC) Panel

Figure 2: MCC PANEL[2]

Gujarat Technological University 2|P ag e Vishwakarma Government Engineering College, Chandkheda

1.2.3 Low Tension Panel

1.2.4 VFD Control Panel

Figure 4 :VFD control panel

Gujarat Technological University 3|P ag e Vishwakarma Government Engineering College, Chandkheda

1.3 Application Area

Gujarat Technological University 4|P ag e Vishwakarma Government Engineering College, Chandkheda

CHAPTER 2 : Control Panels

Types of Control Panel

2.1 Power Control Center (PCC) Panel

Gujarat Technological University 5|P a g e Vishwakarma Government Engineering College, Chandkheda

with provision to connect bus duct at main Incomer side.

Figure 5 : PCC PANEL

• Modular / Non- compartmentalized construction.

➢ Pre-Treatment & Painting

• Three Tank / Seven Tank Pretreatment process

➢ Bus Bar Arrangement & Cable Alley

• Electrical Grade Aluminum / Copper Busbar

Gujarat Technological University 6|P a g e Vishwakarma Government Engineering College, Chandkheda