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Acknowledgement
Sincerely,
Chander Mohan Shah
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Declaration
I hereby declare that I understand and agree to the terms and conditions
outlined for the training program. I acknowledge that participation in this
training is voluntary and that I am committed to actively engaging in all
aspects of the program. I agree to adhere to the rules, guidelines, and
ethical standards set forth by the training provider. Furthermore, I
understand that any materials, knowledge, or skills acquired during the
training are for personal and professional development purposes only and
may not be used for unauthorized purposes. By signing this declaration, I
affirm my dedication to learning and improving my skills in the specified
training area.”
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Abstract
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LIST OF CONTENTS
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List of Figures
8 KitKat fuse 20
9 Cartridge fuse 21
10 High rupturing fuse 22
11 Miniature circuit breaker ( MCB) 23
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Introduction to Control Panels
ENCLOSURE
Enclosure is the metal electrical control box that contains all of the
electrical devices of the control panel. Enclosures are often aluminum
or stainless steel and the size will vary based on the size of the process.
An electrical control panel enclosure can have multiple sections. Each
section will have an access door.
The size of the enclosure is commonly referred to by the number of
doors the enclosure has.
Fig 1
The back panel is a sheet of metal that is mounted on the inside of the
enclosure that allows us to drill mounting holes for different devices
which leads us to our next component, DIN rails.
A DIN rail is a metal rail with a standard width used for mounting
electrical devices inside.
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The next component inside the electrical control panel is wiring Duct.
Ducts allow us to route the wires in an organized and efficient way
while also reducing electrical noise between devices.
Fig 2
SURGE ARRESTER
After the power comes into the panel from the main circuit breaker the
power will be run into a surge arrester.
A surge arrester is a device that protects all of the electrical equipment
inside the control panel from electrical surges or overvoltage. An
electrical surge can come from a lightning strike or utility power surge.
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TRANSFORMER AND 24-VOLT POWER SUPPLY
The power can be connected into a transformer that switches the power
down in order to power smaller devices.
If the incoming power is above 120 volts, a transformer is generally
used.
If the power is 120 volts, a power supply can be used to step the power
down to 24 volts.
Now that the electrical control panel has incoming power from the
main circuit breaker and power distributed by a transformer or power
supply the different voltages can be wired into terminal blocks for even
more routing of power throughout the electrical control panel.
Fig 3
TERMINAL BLOCK
A terminal block consists of two terminals that can join two or more
wires together.
Fig 4
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RELAYS AND CONTACTORS
The PLC outputs will be wired to a bank of relays that will close an
internal contact that will send power out to turn ON or OFF a device
on the assembly line.
Smaller relays will control devices such as lights or fans while a bigger
relay, called a “contactor”, is used to control motors.
Fig 5
Each control panel will have the main power source coming in that
is distributed throughout the panel to varying devices for control
and monitoring.
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Types of Control Panels
Distribution panels
• Main distribution panels
• Sub distribution panels
Changeover panels
• Manual Changeover Panels
• Automatic Changeover Panels (ATS panel)
Motor control panels
o DISTRIBUTION PANELS
Fig 6
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✓ Sub Distribution Panel :
The Main Distribution panel Board then feeds to the Sub
distribution boards, which is installed generally at the point
where a large distribution cable terminates and several smaller
sub-circuits start. The voltages and current ratings are low. These
are the switchboards that although similar construction, are
larger than a final distribution board circuit. The boards are
installed midway through the power distribution system, at the
point in a large distribution cable ends, and several smaller
starting sub-circuits.
o CHANGEOVER PANELS
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✓ Motor Control Panels
Motor Control panel consist of different motor starting
methods such as Direct Online Starter (DOL), Star-Delta
Starter, Auto Transformers, Variable Speed Drives or
• Variable Frequency Drives. Mainly used DOL and
StarDelta methods, 2.10.1. Direct Online Starter (DOL)
panel This is the most common method of starting low
power induction motors, where the starter is connected
directly across the three phase of the supply. However,
the starting current at the moment of switching direct-
on-line can be as high as 6-8 times the rated current. A
Direct Online Motor Starter (DOL) consists of
following components:
• A circuit breaker or fuse (F)
• A contactor ( K1)
• An overload relay (OL1)
• Start button (S1)
• Stop button (S0)
Fig 7
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DOL (Direct OnLine Starter)
Introduction
The simplest form of motor starter for the induction motor is the
Direct Online Starter. The Direct Online starter consists 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 condition.
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. i.e. the contactor is electrically
latched closed while the motor is operating.
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mechanical systems such as rotor shaft, bearings, gearbox, coupling,
chain drive, connected equipment’s, etc. leading to premature failure
and plant down times.
6. Voltage dips.
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.3
4. Rural customers to use reduced-voltage starters for motors larger than
10 kW.
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Variable Frequency Drive (VFD)
Introduction
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motor, main drive controller assembly, and drive/operator
Interface.
▪ AC motor
▪ Controller
▪ Drive operation
Fig 8
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Basic tools
• Hammer
• Screwdriver (Slot-head)
• Phillips Screwdriver
• Pliers
• Hacksaw
• Allen Keys
• Side Cutter
• Wrench
• Measuring Tape
I was able to practice the process of panel assembling and panel wiring
in Asian power control.
• First of all, the panel box, cover plates, panel door, mounting
plate and benches were selected according to the given drawing.
• Door arrangement was fixed by using Panel hinge according to
general arrangement.
• The door Beading and panel key mount was attached to the door.
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• The cover plate bracket was prepared by using drill machine, tap
cutting tool, flat screw driver.
• Switch gear benches and din rails were arranged on the mounting
plate according to drawing.
• Mark holes position to fix the benches, din rail bracket, profile
using pencil and drilled all holes using drilling machine.
• Taped all holes using tap cutting tool.
• Din rails and benches were fixed by using flat screw.
• Arrange bus bars, bus bar insulators, neutral link, neutral bar,
earth bar, earth link as general arrangement using bus bar bend
machine.
• Made the holes to fix bus bar insulators, earth link, and neutral
link etc. on mounting plate and all holes were taped.
• All items were fixed according to general arrangement using
proper tools.
• The door arrangement of indicators and other equipments was
prepared according to drawing by using drill machine and Jig
saw.
• All electrical equipments were fixed in to the proper place and
mounting plate was fixed in to the panel box.
• The cable ducts was cut in to suitable size and fixed in to the
panel box.
• The relevant wire size was selected according to current rating
chart.
• The cable length was defined and cut the wires using wire cutter.
• The Lug was fixed to the wires using lug cramping tool and End
cap was fixed in to the cable according to phase colour.
• Wiring was done according to the wiring diagram, Allen key,
Phillips and flat screw drive.
• Marked the tighten nut using permanent maker pen.
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• Checked the wire connection, cable size and connection.
Fuses :
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Fig 9
Cartridge Fuse :
21
Fig 10
Fig 11
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Miniature Circuit Breakers (MCB)
Type C – operate 5-10 times rated current and suitable for lighting
and motor loads.
Type D – operate 10-20 times rated current and suitable for heavy
units, welding plant
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Fig 12
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Fig 12
Overload Relay
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Fig 13
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Measuring Devises Used in the Panels
Current Transformer
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Ammeter
. Fig 15
Voltmeter
Fig 17
Contactor
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is depending on its category. The categories in standard are
described as:
-1 - Non-inductive or slightly inductive loads, resistance
furnaces
-2 - Starting of slip-ring motors: starting, switching-off
-3 - Starting of squirrel cage motors. (Inductive and
resistive loads)
-4 - Starting of squirrel-cage motors with inching and
plugging duty.
Fig 18
Timer Relay
Timer relays are simply control relays with a time delay built
in. Their purpose is to control an event based on time. The
difference between relays and time delay relays is when the
output contacts open & close: on a control relay, it happens
when voltage is applied and removed from the coil; on time
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delay relays, the contacts can open or close before or after
some time delay.
Fig 19
I used test lamp for find simple faults or detect and presence
or absence of voltage at each point. The test lamp was an
electric lamp connected with two insulated wire leads. Also
it was used for identification the approximate voltage (230
or 415V) by using the brightness of the lamps.
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be measured, without having to make physical contact with
it, or to disconnect it for insertion through the probe.
Fig 20
. Fig 21
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• Megger
The Megger tester is a method of testing making use of an insulation
resistance meter that will help to verify the condition of electrical
insulation. The tester generates a high DC voltage of around 500V
to 5KV or more. In distribution panels, insulation resistance more
than 5 MΩ, it has enough insulation resistance.
Fig.: - 22
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symbols across pages or projects. It helps businesses number
components, generate cable names and terminal numbers, and check
for duplicate components.
The system automatically renumbers contacts, supports hyperlinks on
graphics and lets supervisors copy symbols across projects. SEE
Electrical also offers multiple symbol libraries with a graphical
overview and grouping or searching capabilities.
I was able to draw a diagram on SEE Electricals. The diagram is
shown below:
Fig 23
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Conclusion
Industrial training plays a significant role in students life to develop new
skills. Student should aware of what the present society holds for them
and adapt accordingly. All skills depends on your knowledge and your
ability and your determination. So adopt this chance and utilize your
knowledge during industrial training
References
▪ www.electricaltechnology.org
▪ www.geeksforgeeks.org
▪ www.electrical4u.com
▪ https://www.automationreadypanels.com
▪ www.electricaltechnology.org
▪ https://en.m.wikipedia.org
▪ https://hermitageautomation.com
▪ https://circuitglobe.com
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