I.

K Gujral Punjab Technical University

Main Campus, Kapurthala (Punjab)

Department of Electrical Engineering

Industrial Training Report

( BTEE-721-18)
On
Electrical Panels and Starters
Academic Session January - June ( 2024)

Submitted to : Submitted by:

Dr. Akhil Gupta. Chander Mohan Shah
( Assistant professor ). Roll No. : 2124539
Department of electrical engineering B.Tech ( 8 Samester )

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. Batch : 2021 - 2024
Acknowledgement

I would like to express my sincere gratitude to Shiv Electrical Works for

providing me with the opportunity to participate in the summer training
program.
I am thankful to Shiv Shankar Shah for their guidance, support, and
valuable insights throughout the training period. Their mentorship has
been instrumental in enhancing my skills and knowledge in
electromechanical panel .
I also extend my appreciation to Dr. Y.S Brar (head of Electrical
Engineering department) and assistant professor Dr. Akhil Gupta for their
guidance, encouragement and valuable suggestion which is extremely
useful and helpful in completing this training.
Thank you once again for this valuable opportunity.
Sincerely,

Chander Mohan Shah

Roll no. – 2124539

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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.”

Date: ( Signature of student)

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Abstract

Electrical panels serve as the backbone of electrical distribution systems,

facilitating the safe and efficient supply of electricity to various consumer points.
This abstract explores the integration of advanced technologies to enhance the
performance, safety, and reliability of electrical panels. The adoption of smart
monitoring systems enables real-time data collection and analysis, allowing for
predictive maintenance and early fault detection. Additionally, the implementation
of intelligent circuit breakers and surge protection devices enhances overcurrent
and overvoltage protection, safeguarding equipment and preventing electrical
hazards. Furthermore, advancements in energy management systems optimize
energy usage within electrical panels, contributing to cost savings and
environmental sustainability. Through the integration of these innovative
technologies, electrical panels are poised to meet the evolving demands of modern
electrical systems while ensuring enhanced safety and efficiency.

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 LIST OF CONTENTS
Page Topic Page No.
No.
1. Introduction to control panel 1 - 10
 Enclosure
 Main circuit breaker
 Surge arrester
 Transformer and 24 volt power
supply
 Terminal box
 Relays and contactor
2. Types of control panel 11 - 13
 Distribution panel
 Changeover panel
3. DOL ( Direct Online) starter 14 - 15
 Advantages
 Disadvantage
4. VFD ( Variable frequency drive) 16 - 17
5. Tools and machines used in control 18
panel
6. Panel assembly procedure 19
7. Power circuit wiring 20
8. Electrical protective device used in 21 - 25
panels
9. Measuring device used in panels 26 - 27
10. Switching Device used in panels 28 - 30
11. Electrical panel testing 31 - 32
12. Conclusion 33
13. References 34

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 List of figures

Figure No. Name of figure Page No.

1 Enclosure 7
2 Main circuit breaker 8
3 Terminal box 9
4 Relays and contactor 10
5 Distribution panel 11
6 Motor control panel 13
7 Variable frequency drive ( VFD ) 16

8 KitKat fuse 20
9 Cartridge fuse 21
10 High rupturing fuse 22
11 Miniature circuit breaker ( MCB) 23

12 Surge protection device 24

13 Thermal overload relay 25
14 Current transformer 26
15 Ac ammeter 27
16 Ac voltmeter 28
17 Relay 29
18 Contactor 30
19 Timer 31
20 Clamp meter 32
21 Continuity meter 32
22 Megger 33

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 Introduction to Control Panels

Electrical Control Panels is a metal box which contains important

electrical devices that control and monitor a mechanical process
electrically. The following are the main parts of 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

 BACK PANEL, DIN RAILS, WIRING DUCTS

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.

 MAIN CIRCUIT BREAKER

The main circuit breaker is where the power comes into the control
panel for all of the devices. This circuit breaker generally has a
disconnect on the outside of the panel that allows us to shut off the
power.
Always remember the topside of the circuit breaker will still have
power. The power that comes into the panel can be anywhere from
480 volts to as low as 120 volts.

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.

Types of Control Panels

Distribution panels
• Main distribution panels
• Sub distribution panels
Changeover panels
• Manual Changeover Panels

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 • Automatic Changeover Panels (ATS panel) Motor
control panels

o DISTRIBUTION PANELS

 Main Distribution Panel :

Main Distribution panel Board (MDB) is a panel or
enclosure is used to distribute electrical power to numerous
individual circuits or consumer points, is taken in from the
transformer or an upstream panel. An MDB typically has a
single or multiple incoming power sources and includes
main circuit breakers and residual current or earth leakage
protection devices. A MDB is comprised of a free standing
enclosure, a bus bar system, MCCB's, metering and support
equipments and required current transformers. Panels are
assembled in a systematic manner such as incomer section
and outgoing section.

Fig 6

 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,
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 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

In Automatic Changeover Panels we used several types of Auto

transfer Switches (ATS). MCCB type, Contactor type and
Changeover type were some of them. A changeover panel is
operating on a mains power failure system. There are two types
of changeover panels.
 Manual Changeover Panel :
In manual changeover panels rotary manual switch with centre
off position is used to enable selection of 2 different supplies.
Most commonly a mains supply and a back-up generator supply.
 Automatic Changeover Panel (ATS panel) :
The automatic panel, when the main supply is interrupted on one
or all phases (after an adjustable delay period) the generator sets
will start-up automatically. After an initial warm-up period
(adjustable) the generators will synchronize with each other by
means of motorized circuit breakers or contactors onto a
common bus bar. When the power will come, the motorized
change-over switch will be closed and the load will be
connected to the main supply.
 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
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 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

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.
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 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.

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.

Dis-advantages 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.

Features of DOL starter

1. For low- and medium-power three-phase motors

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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.

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.
Variable Frequency Drive (VFD)
Introduction

Variable frequency drive is a combination of diode, de and

ac current, IGBT and three phase supply. This is also called
adjustable-frequency drive, variable-speed drive, AC drive,
micro drive or inverter drive.
“Variable frequency drive is electro-mechanical drive
systems to motor speed and torque by varying motor input
frequency and voltage.” You can divide the world of
electronic motor drives into two categories: AC and DC. A
motor drive controls the speed, torque, direction and

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resulting horsepower of a motor. A DC drive typically
controls a shunt wound DC motor, which has separate
armature and field circuits. AC drives control AC induction
motors, and-like their DC counterparts-control Speed,
torque, and horsepower.
Constant torque and constant power are fixed in variable
frequency drive.

Principle and Working

When we are given to AC supply to drive then in first stage

the AC is passes through diode (diode is convert is ac to de)
then AC is convert into pure DC supply, now in second
stage the IGBT is connected in series with diode. IGBT is a
three terminal device that is convert ac to de and de to ac
accordantly. Then the pure or filter de current is passes
through in the IGBT then the de is again convert in ac
current that current is also called controlled three phase ac.
A variable-frequency drive is a device used in a drive system
consisting of the following three main sub-systems: AC
motor, main drive controller assembly, and drive/operator
Interface.
 AC motor
 Controller
 Drive operation

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 Fig 8

VFD system is usually a three-phase induction motor. Some

types of single-phase motors can be used, but three-phase
motors are usually preferred.

Variable Frequency Drive rating and type

 Voltage-source inverter (VSI) drive topologies

 Current-source inventer (CSI) drive topologies
 Six-step inverter drive topologies
 Load commutated inverter (LCI) drive topologies:

Tools & Machines used in workshop

When I was assembling the panels in the workshop, Following

tools and machineries were used. Before I used these tools and
machineries safety rules and operating instruction were followed
correctly

Basic tools
• Hammer
• Screwdriver (Slot-head)
• Phillips Screwdriver
• Pliers
• Hacksaw
• Allen Keys
• Side Cutter
• Wrench
• Measuring Tape

Panel accessories used in workshop

• Panel plate
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 • Panel hook
• Panel holder
• Panel hinge / Chrome hinge
• Panel key
• Beading
• Cables ties
• Name plates & danger stickers
• Earth bar

Panel assembling Procedure

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.
• 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.

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• 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.

Power circuit wiring procedure

• 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.
• Checked the wire connection, cable size and connection.

Control circuit wiring procedure

• Auto cable was used to wire the control circuit.

• The cable length was defined and cut the wire using side cutter,
wire striper.
• Print the tube number using ferrule print machine.
• Lugs were fixed to cable using cramping tool.
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 • The control side was wired by including numbers, Phillips and
flat screw drive were used.
• Wire combines between control side and power side.
• The control line was neatly arranged by using spirals and cable
ties.
• Checked the wires connection

Electrical Protective Devices Used in the Panels

The electrical panel was designed with protective devices. Protective

devises were used for human protection, system protection and
equipment protection. In Orange Electrical panels were consisted with
various types of protective devises. I was able to get knowledge about
using purpose, working principle, connection and testing of these
protective devices.

Fuses :

Fig 9

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 A fuse is a type of protection device in electrical applications. Fuses are
designed to open circuits the filament when excessive currents are
present due to overloads or faults and to prevent further damage to the
system. Short circuit, system overload, other device failures, lightning,
static electricity or system overload are some common results in blown
fuses.

Cartridge Fuse :

In cartridge fuse the fuse wire is enclosed in a transparent glass

tube or bulb, the whole unit is sealed off. In case the fuse blows,
it is to be replaced by new one as the cartridge fuse can not be
rewired due to its sealing. In cartridge type fuses have many
other sub types as MCB type, screw type, etc.
Fig 10

HRC Fuse (High Rupturing Capacity Fuse) :

HRC Fuse consists of highly heat resistant material (such as

ceramic) body having metal-end caps, which is welded by
silver current carrying element. HRC Fuse has high
rupturing capacity. It has constant fusing characteristics and
operates fast.

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 Fig 11

Miniature Circuit Breakers (MCB)

In electrical panels, MCB was used as the basic protective device.

MCBs are designed to automatically protect against overloads and
short circuits, preventing damages cables and equipment. Trip
characteristics normally can not adjustable. MCB has
thermalmagnetic operation. Over current protection is got the
system by the thermal trip unit of the breaker. Short circuit
protection is got to system by the magnetic Trip unit of the
breaker. The MCBs‟ are in single pole, double pole, try pole and
four pole types every circuit breaker has a voltage rating that
designates the maximum voltage it can handle and a continuous
current rating, which is the maximum continuous current carry
without tripping. The value of the kA rating, determines how
much current the circuit breaker can withstand under fault
conditions. When we consider MCBs we can see various MCBs
with different ampere ranges and internal situations (Tripping).
MCBs are classified according to the ampere. Type B – operate 3-
5 times rated current and suitable for lighting loads

Type C – operate 5-10 times rated current and suitable for

lighting and motor loads.

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 Type D – operate 10-20 times rated current and suitable for
heavy units, welding plant

Fig 12

The Surge Protection Device

The Surge Protection Device (SPD) is a component of the

electrical installation protection system. This device is connected
in parallel on the power supply circuit of the loads that it has to
protect. It can also be used at all levels of the power supply
network. This is the most commonly used and most efficient type
of overvoltage protection. It is a device used on power systems
above 1000V to protect other Equipments from lightning
switching & surges. It Does Clamp (limit) the Voltage produced

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 by the Lightning. It only protects equipment electrically in parallel
with it.

Fig 12

Overload Relay

The overload is a heat operated relay where a coil heats a

bimetallic strip and releasing a spring to operate contacts. It has
NO & NC auxiliary contact points for the controls. If the overload
senses excess current in the load, the coil is de-energized. Electric
motors need over current protection to prevent damage from
overloading the motor, or to protect against short circuits in
connecting cables or internal faults in the motor windings.

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 Fig 13

Measuring Devises Used in the Panels

Current Transformer

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 Current transformers can reduce or "step-down" current levels
from thousands of amperes down to a standard output of a
known ratio to either 5 Amps or 1 Amp for normal operation.
CTs are used with watt meters, power factor meters, watt-hour
meters, protective relays and metering applications, because
they are insulated away from any high-voltage power lines. Its
primary winding is just a conductor or bus bar placed through
a central hole. The secondary winding may have a large

number of coil turns wound on a laminated core as shown

below.
Fig 14

Ammeter

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 An ammeter is a measuring instrument used to measure the
electric current in a circuit. Current transformers and
ammeters are used together as a matched pair in which the
design of the current transformer is such as to provide a
maximum secondary current corresponding to a full-scale
deflection on the ammeter. For most current transformers
the primary and secondary currents are expressed as a ratio
such as rated current : 5A.

. Fig 15

Voltmeter

A voltmeter is an instrument used for measuring electrical

potential difference between two points in an electric circuit.
Analog voltmeters move a pointer across a scale in proportion
to the voltage of the circuit. The voltmeter selector switch is
used to select the two phases or phaseneutral in 3 phase
system.

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 Fig 16

KWH Meter (Energy meter)

KWH Meter is used to measure the kW power. Mainly we use

two types of KWh meters. Those are single-phase kWh meters
and three phase kWh meters. These three phase & single phase
meters are can be dividing again like this C/T type and direct
type. Mostly we use C/T type energy meters. In some panels,
used digital KWH meters.

Switching Devises Used in the Panels

Relay

A relay is a switching device. Relays are used where it is

necessary to control a circuit by a low- power signal with
complete electrical isolation between control and controlled
circuits or where several circuits must be controlled by one
signal. Relay consists with coil, normally open and normally
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closed contact points. When current starts flowing through the
control coil, the electromagnet starts energizing and contact
points are changed their position. Coil voltage can be 12V to
230V AC or DC. Also contact current rating is important
factor. According to the contact pin arrangement, relays are
categorized as 8 pins, 11 pins, 14 pins and etc. relay is fixed
with its base.

Fig 17

Contactor

It was used for the high power application switching on power

circuit. Also I connected timers, auxiliary contact points (side
and top), timers and mechanical interlock to the contactors
according to the requirement. A contactor consists of mainly 2
parts-Fixed and movable jaws. the fixed jaws are firmly
connected with the circuit and is a provided with a coil having
movable jaw as soon as current is allowed to flow from the
circuit the coil gets charged and due to electromagnetic effect
it attracts the movable metal jaw, thus the circuit is complete
with the contact provided by the movable jaw. This is the
functioning of contactor. When current through the coil loss,
coils demagnetize and open the contacts. The coil consist with
shaded pole core, because of avoiding the current zero position
of the AC supply. The current rating of the contactor is

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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

Electrical Panel Testing

The following testing equipments were used to check the
conditions of the panels.

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.

Clamp meter is an electrical device having two jaws which

open to allow clamping around an electrical conductor. This
allows properties of the electric current in the conductor to

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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

A continuity tester is an electrical test equipment used to

determine if an electrical path can be established between two
points that is if an electrical circuit can be made. The circuit under
test is completely de-energized prior to connecting the apparatus.
The tester consists of an indicator in series with a source of
electrical power - normally a battery, terminating in two test
leads. If a complete circuit is established between the test-leads,
the indicator is activated.

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. Fig 21

 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

Introduction to SEE Electricals

What is SEE Electrical?

SEE Electrical is an electrical CAD software designed to

help businesses create wiring diagrams on a unified
platform. It offers real-time lists for terminals, parts, cables,
wires, contacts, documents, or other components and lets
managers import images in multiple formats such as BMP,
PCX, PDF, PNG, JPG, and more.

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SEE Electrical enables organizations to create custom
symbols, drawing macros and templates for projects,
organize diagrams into folders, and lock component names,
terminals, or wire labels. Supervisors can compare
workspaces, generate reports, import assignment lists in
Microsoft Excel format and find and replace 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:

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 Fig 23

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

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 References

 www.electricaltechnology.org

 www.geeksforgeeks.org

 www.electrical4u.com

 https://www.automationreadypanels.com

 www.electricaltechnology.org

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 https://en.m.wikipedia.org

 https://hermitageautomation.com

 https://circuitglobe.com

 Electrical System Design by M.K. Giridharan Company

Profile

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