INDEX

1. Introduction

1.1. Problems Encountered During Motor Starting:

1.2 .Star Delta Starter

1.3 .Components of a Star-Delta Starter

1.4. Contactors

1.5. Timer

1.6. Interlock Switches

1.7. Thermal Overload Relay

1.8. Induction Motor Winding Terminals Connected In Star and Delta Configuration

2. Literature Review

2.1. Fast Starting Method Using both Inverter and Delta-Star Starter for
Weaving Machine Drive Systems - 2013

2.2. Assessment and Comparison of Conventional Motor Starters and Modern

Power Electronic Drives for Induction Motor Starting Characteristics – 2009

2.3.Implementation and Analysis of Microcontroller Based Soft Starters for

Three Phase Induction Motors – 2007

2.4. Development and Analysis of Novel Soft-Starter/Energy-Saver Topology

for Delta-Connected Induction Motors- 2005

2.5. Research on DTC Control Strategy of Induction Starter/Generator System-

2005

2.6. Low Impact Motor Control with Star-Delta Starting- 1998

2.7. Electric Motor Starters- 1922

1
3. Methodology

3.1 Background

3.2 Objective

3.3 Principle

3.4 Working

3.4.1 Working of Star-Delta Starter

3.4.2 Terminal Connections in Star and Delta Configurations

3.4.3 Working of Mobile Interface

3.4.3.1 Mobile Interface:

3.4.3.2 DTMF

3.4.3.3 DTMF Decoder

3.4.3.4 MT8870

3.4.3.5 Construction of Mobile Interface

3.4.3.6 Decoding for Mobile Interface:

3.4.4 Programmable Logical Controller (PLC)

3.4.4.1 Construction of PLC

3.4.4.2 PLC Programming Languages

3.4.4.3 Ladder Diagram (LD)

3.4.4.4 PLC Ladder Programming Conventions

3.4.4.5 Necessity of Programming

3.5 Functioning of Flow Chart:

4. Data Collection / Tools/ Platformed Used

4.1 General Information of Main Components.

4.1.1 Miniature Circuit Breaker(MCB)

4.1.2 Power Contactor :

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 4.1.3 Add on Blocks:

4.1.4 Over Current Relay(4/8)

4.1.5 Ammeter

4.1.6 Timer

4.1.7 Relays

4.1.8 Neutral Link

5. Design/Implementation

5.1 Drilling on the Door

5.2 Mounting of Door

5.3 Painting

5.4 Mounting of the Indicators

5.6 Assembly of Components

5.6 Control Wiring and Power Wiring

5.7 Mounting of Plate in the Panel

6. Testing and Summary of Result

6.1 Testing of Components

6.2 Testing of Power and Control Circuit

6.3 Testing of Mobile Interface Circuit and Interface with Panel

7. Reference

7.1 For Reverse Forward Drive with Star Delta Starter:

7.2 For Mobile Interface

7.3 For PLC Interface

3
 Chapter 1

INTRODUCTION

4
 1 INTRODUCTION

We have combined the idea of phase sequence with the star delta type of starter
because mostly industry uses DOL starter for such type of drive. Most of the induction
motor are directlystarted on line, but when very large motors are started that way, they
cause a voltage disturbance on the supply lines due to large starting current surge 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
autotransformer starting.
The designing aspect of our panel basically consists of power wiring and control
wiring scheme. The internal structure of panel is having single pole MCB, 3pole MCB,
timer, contactors, overload relay, connectors block and power terminals. On the outer
frame there are 4 indicators for forward, reverse, trip and off and 3 switches for Forward
ON, Reverse ON and OFF.We had used minimum components for our panel and made it
attractive and user friendly so that it can be easily operated.
We had done detailed study in the field of switchgear and electrical panel
Studied about the wiring scheme of control and power wiring and also about different
components which are used in electrical panel such as MCBs, Contactors, relays etc.
why they are used and what is the purpose.
MCBs are used for protecting the entire circuitry from direct supply of power.
Contactors are used for performing operation which is required and relays are also used
for protection from short circuit if occurs due to heavy current surges.
We made a Reverse forward drive with star delta starter which is basically used
for protection purpose of motor. It can be used for 3-5Hp ratings of motor. We can
implement our technique of Reverse forward with star delta for such industrial

5
application where the reverse forward motion is required. Instead of using other types of
starter we have used star-delta type because it will not damage motor when started
directly and prevent from current surges as other type of starter will not provide such
protection. For star delta starter we need five contactors as other industry uses but we
have used only four contactors combining both for reverse forward and star delta.
Also as per advancement and innovation required we added a additional feature of
mobile interface, So that we can operate our panel automatically through mobile from
any location. In these we used a DTMF IC which will perform the entire operation.
A 3 Phase Induction motor consists of a stator which contains 3 phase winding
connected to the 3 phase AC supply. The arrangement of the winding is so as to produce
a rotating magnetic field. The rotor of the Induction motor contains cylindrical core with
parallel slots that contain conductors.

1.1 Problems Encountered During Motor Starting:

The most basic feature of an Induction motor is its self starting mechanism. Due
to the rotating magnetic field, an Emf is induced in the rotor, because of which current
starts flowing in the rotor. As per the Lenz law, the rotor will start rotating in a direction
so as to oppose the flow of electric current and this gives a torque to the motor. Thus the
motor gets self started.

During the self starting period, as torque increases, the large amount of current
flows in the rotor. To achieve this the stator draws a large amount of current and by the
time the motor reaches its full speed, a large amount of current is drawn and coils get
heated up, damaging the motor. Hence there is a need to control the motor starting. One
way is to reduce the applied voltage, which in turn reduces the torque.

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1.2 Star Delta Starter:

In star delta starting, the motor is connected in STAR mode throughout the starting
period. When the motor reached the required speed, the motor is connected in DELTA
mode.

1.3 Components of a Star-Delta Starter:

1.4 Contactors:

The Star- Delta starter circuit comprises of three contactors: Main, star and delta
contactors. The three contactors are solicited to unite the motor windings first in star and
afterward in delta.

1.5 Timer:

The contactors are regulated by a timer incorporated with the started.

1.6 Interlock switches:

Interlock switches are connected between star and delta contactors of the control
circuit as a safety measure so one can’t activate delta contactor without deactivating star
contactor. By any chance if star and delta contactors are actuated at the same time, the
motor will be damaged.

1.7 Thermal overload relay:

A thermal over-load relay is likewise consolidated into star-delta control circuit to

ensure the motor from intemperate heat which might expedite motor finding fire or
wearing out. In the event that the temperature goes past a preset quality, the contact is
open and power supply is cut in this manner ensuring the motor.

1.8 Induction Motor Winding Terminals Connected in Star and Delta :

The point when delta contactor closes, the motor winding terminals U2, V2 and
W2 get associated with V1, W1 and U1 individually through the shut contacts of primary

7
contactor. That is for delta association, fulfilling end of one winding is to be joined with
beginning end of the other winding. The motor windings are reconfigured in delta by
supplying line voltage L1 to winding terminals W2 and U1, line voltage L2 to winding
terminals U2 and V1; and line voltage L3 to winding terminals V2 and W1, as indicated
in figure.

As many industries uses DOL starter for starting purpose of motor we choose to
use star delta for smooth operation of reverse forward motion of the motor as it will
protect motor from heavy current surges. And in the above mentioned paragraph we
would conclude that star delta starter is most efficient starter.

Chapter 2
LITERATURE
REVIEW

8
 2 LITERATURE REVIEW

2.1 Paper[1] Fast StartingMethod using both Inverter and Delta-Star

Starter for Weaving Machine Drive Systems.
Authored by: Masakazu Kato, Koji Orikawa, Jun-Ichi Itoh and Noboru
Saitoh

Date of Publication: 2013

This paper proposes a fast accelerating method for the weaving machine drive
system, which an open winding of the induction motor is used and connected in series to
an inverter and a switching unit.Generally, the star (Y) - delta ( ) switching method is
used in the start-up mode in order to suppress the rush current in general applications.
However, in weaving machine, the rush current is required in the start-up mode in order
to increase starting torque. If the starting torque is not enough to the induction motor,

9
deficiencies of fabric cloth which is called "start-up marks" will happen. That’s why they
proposed the -Y switching method that achieve high rush current in order to increase
starting torque for weaving machine drive system. From the experimental results, the
start-up time of the proposed system is kept to the same as the direct power grid
connection. In addition, rush current of the proposed system is decreased to 37.7%
comparing to the direct power grid connection.

2.2 Paper [2] Assessment and Comparison of Conventional Motor

Starters and ModernPower Electronic Drives for Induction Motor
Starting Characteristics.

Authored by: K. Pillay, M. nour, K.H. Yang, D.N. Datuharun and L.K.
Haw

Date of Publication: 2009

This paper proposes that the induction motor is the workhouse of industry and
particular attention is required to monitor and control it.An induction motor draws a high
starting current anddevelops a high torque during start-up. The high startingcurrent often
causes problem such as voltage dips whichwill be penalized by the energy companies.
Various motorstarters were introduced to overcome this problem. These include
bothconventional electromechanical starters and powerelectronic drives. This paper will
also provide asuggestion of which starter is most suitable for anapplication based on the
stated constraints.

2.3 Paper[3] Implementation and Analysis of Microcontroller Based

Soft Starters for Three Phase Induction Motors

Authored by: Hamdy A. Ashour and Rania A. Ibrahim

Date of Publication: 2007

This paper introduces two different microcontrollerbased three phase induction

motor starters, the firstusing electromechanical star-delta with reactor starting andthe
second utilizes electronic AC voltage controllers startingtechnique. For each of the

10
proposed methods, the experimentalsetup is implemented and the output voltage,
currentand speed waveforms were demonstrated and analyzed fordifferent selection
options and operating conditions. A dynamicmodel of three phase induction motor has
been developedto validate a model of six terminals connection motorfor star and delta
performance analysis. The model has beenutilized for the simulation analysis and
comparison of variouselectromechanical and electronic induction motor
starterstechniques. Comparison between commercial analogcontroller based soft starter
LH4-N2 and the proposedstarter has been introduced as well. Experimental and
simulationwaveforms obtained are matched validating the proposedstarters for practical
applications.

2.4 Paper [4] Development and analysis of novel soft-starter/energy-

saver topology for delta-connected induction motors

Authored by: K. Sundareswaran and B.M. Jos

Date of Publication: 2005

This paper proposes that a thyristorised star/delta switch is proposed as a soft

starter and energy saver for deltaconnectedinduction motor drives. A low-cost
microprocessor-based hardware is developed andused for the control of the star/delta
switch. The use of the star/delta switch for starting is firstexplained followed by its
application as an energy saver. Three schemes of switching transitions areproposed and
implemented for the star (delta) to delta (star) changeover process. Extensivesimulation
and experimental results are presented to show that the proposed circuit is a
promisingcandidate as a starter/energy saver for delta-connected induction motor drives.

2.5 Paper[5] Research on DTC Control Strategy of Induction

Starter/generator System

Authored by: Zhang Lanhong, Hu Yuwen and Huang Wenxin

Date of Publication: 2005

This paper proposes that the advancement in power electronic makes thecage-
type induction machine(IM) be suitable to be used as astarter/generator(S/G). Because

11
the IM must start the engineto a high ignition speed with a low voltage battery,a
methodwhich employs delta-connection stator winding is proposed.Similarities and
differences of basic direct torquecontrol(DTC) in IM with delta-connection and
starconnectionstator winding are investigated. In order toconvert the IM from starting
mode to generating mode, smoothly, a method by changing the direction
ofelectromagnetic torque is presented. The disadvantage ofbasic DTC is that it has a big
torque ripple. In generating mode,the torque ripple can cause voltage ripple. In order
todecrease voltage ripple, DTC based on space vectormodulation(SVM-DTC) is
researched. Creation method ofreference voltage vector which includes change trend
andmagnitude information of flux and torque is presented.Experimental results verify
that the inductionstarter/generator system can successfully start the enginewith the low
voltage battery and can convert from startingmode to generating mode, smoothly under
basic-DTC. Thesystem has a preferable stable and dynamic generationperformance under
SVM-DTC.

2.6 Paper [6] Low Impact Motor Control with Star-Delta Starting

Authored by: Phillip W. Rowland

Date of Publication: 1998

This paper proposes that the starting motors using 'across-the-line' techniques
have a heavy impaction the power delivery system. For rural, power capacity limited and
Emergency delivery systems or storefront manufacturing operations this is unacceptable.
With the interest inworld trading, exporters must be aware that most foreign countries
areless tolerate of high motor starting currents than domestic users. Thetechnical
expertise ofthe foreign plant maintenance staff may not support electronic starters which
reducestarting currents. Three phase STAR-DELTA starting arrangements, a well known
but ofbypassed technique, can meet the requirements IF the associated reduced starting
torque isacceptable. This paper will review the calculation methods for determining
startingcurrents and torques. Procedures for selecting the correct motor overload devices,
motorbranch circuit wire sizes and starting device configurations are presented.

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2.7 Paper [7] Electric Motor Starters

Authored by: J. Anderson

Date of Publication: 1922

This paper proposes that the practical development of anelectric motor starter
from the first principles relating tocurrent, torque, and resistance values, to the data
requiredby the salesman.First it describes the method adopted of working in
percentagesfor all calculations; defines what is meant bystarting, accelerating and
running torques; refers to thelack of data regarding starting conditions; and gives tablesof
stored energy in rotors, for the normal load torque duringacceleration and for the stored
energy of a number oftypical machines.Accelerations are classified as "natural regular,"
"natural irregular", "forced regular", and "forced irregular", andtypical diagrams with
automatic contactor and handoperatedstarters are shown.The rating of the resistance
elements, and points arisingout of continuous and intermittent rating, together
withdiagrams for air cooling, and radiation and diffusion curvesfor oil-immersed
resistances, are next dealt with..

Chapter 3

METHODOLOGY 13
 3 METHODOLOGY
3.1 BACKGROUND

The basic idea behind our project is somewhat established during our internship
days. We have done internship in sigma electrical private ltd. which is company of
different types of panels. In this industry, according to the user’s requirement assembling
of panels can be take place. So while studying different panels such as automatic power
factor corrector panel, auto feed pump panels etc, we came to know that for safe starting
of drives they are using star delta starter as in common practice and for forward reverse
operation they are using cranes according to the load requirements. Here comes spark in
our mind as we thought over the idea that what if we prepare the drive combining the

14
safe starting as well as reverse forward technique so we first share our thought with
company supervisor and asked him whether it is practically possible or not Then we also
refer the IEEE papers published in national and international conferences, but we were
unable to find the combined data useful for this purpose. Either we found data related to
reverse forward alone or we found data related to star delta starter alone. One another
important thing is that VFD’s are having all the advantages compared to drive we
thought of. Due to this major issue we again start searching the things can made our
drive somewhat different from VFD’s but also having the advantages of VFD’s. Today is
the world of atomization; all the industries are fully atomized with the help of PLC and
SCADA system. So we also decided to made drive which is fully atomized and
supported by both PLC and SCADA system. Another important feature we thought of is
wireless controlling of entire drive. In other words, it is also called as mobile interfacing
control. The purpose behind this incorporation is that drive can be controlled from
anywhere in the world if the user knows the operating code specified by the designer.
The ammeter is mounted for measurement of current voltmeter is mounted for
measurement of voltage similarly, we are planning to mount speedometer in terms of
measuring the speed. This is rough idea behind the project we thought of. About this we
talk to our project guide, company supervisor, senior engineers etc. and after their green
signal towards this idea we started the search for components their ratings different
power and control diagrams specific values of current and voltages different load
conditions single phase and three phase analysis of the entities etc. So in other words we
can say that our project is broadly divided into 2 sections software part and hardware
part. Hardware part is somewhat mechanical related things where we have to work
actually on our idea which we have confirmed through software applications. The power
diagrams and control diagrams are made in software. So we have to be learned that
software for this purpose. While doing the exact procedure we faced many difficulties
but by constant searching for how these difficulties overcome and guidance of company
people we are able to make the project.

3.2 OBJECTIVES

 The main objective behind our project is to give protection to the induction motor
from current
surges.

15
  To practically apply and observe the phase sequence reversal.
 The second important objective is any machine or mechanism which requires
reverse forward
Action for its working can be used such types of drives along with protection to
current surges.

3.3 PRINCIPLE OF OPERATION

This is the reduced voltage starting method. Voltage reduction during star-delta
starting is achieved by physically reconfiguring the motor windings. During starting the
motor winding are connected in star configuration and this reduces the voltage across
each winding. This also reduces torque by a factor of three. After a period of time
winding are reconfigured as delta and the motor runs normally.

3.4 WORKING OF MODEL

As shown in the power diagram, there are 4 contactors for forward, reverse, star
and delta mode of operation.For safety against high voltage and current surges 3 pole
MCB and O/L relay assembly is provided.Motor with phase reversal is also indicated in
fig. which shows the reverse mode of operation for 3- ph I.M.Whether machine is
working in forward or reverse it is completely depend upon the user’s instruction.Let us
assume machine is operating in forward mode, so supply is going to forward contactor
from this contactor it will drives the control to the star contactor for some time interval
(timer interval of 5-7 sec) and then control switch on to delta contactor.
For the reverse mode of operation the 3 delta terminals are reconfigured their
phase sequences along with the 3 star terminals and performs the same steps for
operation as that of forward mode.The panel of star delta starter has two type of wiring
i.e. power wiring and control wiring. The above circuit diagram shows the power wiring.
In this circuit diagram we can see that there is 3 phase power supply i.e. L1,L2 and L3.
And there is earthing for protection. This 3 phase supply 1 st comes to the 3 pole MCB for
tripping purpose after that it goes to the power contactor K1 and K2.
In this circuit K1 contactor worked for forward rotation of motor in which the
phase sequence of supply is R-Y-B. K2 contactor works for reverse rotation of motor in
which the phase sequence of supply is R-B-Y. It should be noted that the contactor K1

16
and K2 should not pick up at the same time. Otherwise short circuit will takes place. The
output supply of K1 and K2 is connected to the motor through the overload relay.
This overload relay trips the circuit when fault occur. There is two more
contactor i.e. K3 and K4. The one side of K3 contactor is shorted to make the star
connection as shown in diagram. The contactor K4 connected to the other terminals of
motor in such a way that if u-v-w terminals of the motor gets the phase sequence R-Y-B
then the z-x-y sequence gets the supply of phase sequence Y-B-R so that it makes the
delta connection. Contactor K3 and K4 are connected through the timer in such a way
that as we start the supply at that time contactor K3 pickups for 6 to 8 second so that
motor start with star connection after that K3 gets off and K4 pickups so that motor
continue the rotation in delta connection. As shown in control diagram, general fuse and
o/l relay are provided against high voltage and current surges. Off/ push button is
provided between the forward reverse assemblies in order to switch on either reverse or
forward assembly.
4 contactors are provided for reverse, forward, star and delta operation
respectively. If user put ON forward button, then forward contactor will pick up.
The interlock is provided between forward and reverse such that while working in
forward mode if user press reverse button it will not perform the reverse function and
continues to work in forward mode. As motor initially requires high starting current, it
must be run in star connection and after smooth starting it will be run in delta connection.

17
 FIG 1) POWER DIAGRAM
In order to tackle this star delta conversion timer is provided. The time span for
the timer is decided by means of applied load conditions. So, depending upon this load 5-
7 sec time interval is set on the timer.In other words, after starting of motor for first 5-7
sec it will be run in star connection and after 5-7 sec it will be run in delta connection
assembly.
The panel of star delta starter has two type of wiring i.e. power wiring and control
wiring. The above circuit diagram shows the control wiring. In this circuit diagram we

18
can see that there is 3 phase power supply i.e. L1,L2 and L3. And there is earthing for
protection. This 3 phase supply 1st comes to the 3 pole MCB for tripping purpose after
that it goes to the power contactor K1 and K2.
In this circuit K1 contactor worked for forward rotation of motor in which the
phase sequence of supply is R-Y-B. K2 contactor works for reverse rotation of motor in
which the phase sequence of supply is R-B-Y. It should be noted that the contactor K1
and K2 should not pick up at the same time. Otherwise short circuit will takes place. The
output supply of K1 and K2 is connected to the motor through the overload relay.
This overload relay trips the circuit when fault occur. There is two more contactor
i.e. K3 and K4. The one side of K3 contactor is shorted to make the star connection as
shown in diagram. The contactor K4 connected to the other terminals of motor in such a
way that if u-v-w terminals of the motor gets the phase sequence R-Y-B then the z-x-y
sequence gets the supply of phase sequence Y-B-R so that it makes the delta connection.
Contactor K3 and K4 are connected through the timer in such a way that as we
start the supply at that time contactor K3 pickups for 6 to 8 second so that motor start
with star connection after that K3 gets off and K4 pickups so that motor continue the
rotation in delta connection.

19
FIG 2) CONTROL DIAGRAM

20
 3.4.1Working of Star-Delta Starter:

At first the primary contactor and the star contactors are shut. After a time
interval the timer signs to the star contactor to head off to the open position and the
primary, delta contactors to head off to the shut position, accordingly structuring delta
circuit.
At the time of starting when the stator windings are star associated, every stator
stage gets voltage VL/√3, where VL is the line voltage. Hence, the line current drawn by
the motor at starting is decreased to one-third as contrasted with starting current with the
windings associated in delta. Likewise, since the torque advanced by an induction motor
is corresponding to the square of the applied voltage; star- delta starter decreases the
starting torque to one- third of that possible by immediate delta starting.
The timer controls conversion from star connection to delta connection. A timer
in star delta starter for a 3-phase motor is intended to do the move from star mode,
utilizing which the motor runs on a decreased voltage and current and produces less
torque – to the delta mode indispensible for running the motor at its full power, utilizing
high voltage and current to transform a high torque.

3.4.2 Terminal Connections in Star and Delta Configurations:

L1, L2 and L3 are the 3-phase line voltages, which are given to primary
contactor. The main motor coils are U, V and W is shown in figure. In star mode of
motor windings, the primary contactor associate the mains to essential winding terminals
U1, V1 and W1.the star contactor shorts the auxiliary winding terminals U2, V2 and W2
as indicated in figure. Notwithstanding when the primary contactor is shut supply arrives
at terminals A1, B1, C1 and consequently the motor windings are energized in star-mode.
The timer is initiated in the meantime moment when star contactor is energized.
After the timer achieves the specified time period, the star contactor is de-energized and
delta contactor is energized.

21
 Fig 3)Terminal Connections in Star and Delta Configurations

3.4.3 WORKING OF INTERFACE CIRCUIT

In this circuit we used CM8870 IC which is also known as dual tone multiple
frequency IC (DTMF). This IC has 18 pins. If we give the sound wave input to the pin 2
&3 by filtering the sound.This IC converts or splits the input sound wave into two
frequencies. These frequencies are converted into binary digits 1 and 0. We get the
combinations of these binary digits as a output from pin no. 11, 12, 13 & 14. This signal
is very low to pick up a relay. That’s why we need to convert this signal into the suitable
voltage i.e. 9V. For this purpose we used L293D IC which is also known as motor driver
IC. This IC takes input signals to the pin 2, 7, 10 and 15. And give the output voltage
which is applied to the pin no.8 from pin no. 3, 6, 11 and 14.
In this case the required voltage is 9V, so we have to apply the 9V to the pin no.8
to get output of 9V.With the help of this voltage we can pick up the relay for switching
purpose. In this project, we can control the panel of star delta starter with the help of
mobile. For this purpose we used mobile interface circuit in the panel. We have to give
the input i.e. sound input of key pad numeric tone of mobile to the circuit. This tone is
converted into the binary digits signal by the circuit. To pick up the relay we need to
amplify the signal, which is done by L293D IC. These output signals of IC8870 is again
fed to the inputs of L293D to the port 2, 7, 10 and 15. Consider the inputs to the port 10

22
and 15. If the input to the port 10 and 15 is 0 and 1 respectively then we get the output
0V and 9V from the port 11 and 14.
So we can use this output voltage to pick up the relay which is connected across
the manual switch on the panel. Now if the operator is far away from the panel and
operator want to start the panel then operator has give a call to the mobile phone which is
connected to the mobile interface circuit. Now when the operator press the keypad 1 then
the sound of that tone is being send to the mobile connected to the circuit. And after that,
this tone is send to the input of the circuit. The circuit converts this tone into binary digit
and again into sufficiently required voltage so that relay gets pickup and panel can be
operated.
1st give a call to the mobile connected to the circuit. It should be noted that the
mobile which is connected to the circuit should not be in silent mode and its auto
received function should be on. At the same time, the phone from which the operator is
calling should be in general mode with high volume of keypad tone. When the operator
is going to make a call on the mobile phone which is connected to the circuit, then the
call is automatically received by the phone. After that if the operator press the key 1 of
keypad, the tone of that key is send to the other phone.
As the phone is already connected to the circuit via headphone the sound of that
tone is fed to the circuit. Where the tone is converted into two frequencies and according
to these frequencies we get
the output of binary digits. These binary digits are fed to the motor driver IC. And we get
the output voltage. Consider the output from DTMF IC of port 13 is 0. This output is fed
to the input of motor driver IC at port no. 15.Then we get the output from the port no. 14
is 0V. Now if we connect the one excitation terminal of relay at port no. 14 and other
terminal to the voltage 9V at that time the relay gets pickup. We can use this relay as a
switch to stars the panel. Similarly different keypad tone give us different output and
with the help of this we can operate 3 to 4 relay. And these relays can be used for many
purposes like to start the panel for forward rotation, reversed direction and to stop the
process.

3.4.3.1 MOBILE INTERFACE:

The "Portable mobile interface" is a wonderful and cheap innovation which can
be used to give any electric device, the ability to be switched on with a mobile phone.
The whole process requires almost no skills and costs very less. The device is a plug and

23
play type, so that you just have to hook up the device you want to control, to the portable
interface device. If You have garden plants, but are too busy to water them? just hook the
pump to the device.
The pump will automatically start working as soon as you call from your mobile
phone. The same goes for every other device. Just plug and call and watch it in action.
The mobile phone has a battery inside, so it makes the whole device portable and
independent of the voltage to be switched.The device is created using a complete
changed thinking to the usual methods in electronics i.e to say that no board is used, no
passive components like resistors or capacitors are used, moreover the whole device is
created by recycling old things. Almost no skill and money is required to make the
project, which is a unique feature of the system. The device can give any electric
appliance, whether it is a bulb or a television, the ability to be switched on with a mobile
phone, some simple alterations can make it more effective and a two control one too, i.e
the ability to turn off too. All you have to do is, just connect the appliance's plug to the
socket on the device and watch it going by the ring from your mobile from any corner of
the world, and that too, free of cost.

3.4.3.2 DTMF

The DTMF (Dual Tone Multiple Frequency) application is associated with digital
telephony, and provides two selected output frequencies (one high band, one low band).
The matrix for selecting the high and low band frequencies associated with each key.
Each key is uniquely referenced by selecting one of the four low band frequencies
associated with the matrix rows, coupled with selecting one of the four high band
frequencies associated with the matrix columns. The low band frequencies are 697, 770,
852, and 941 Hz, while the high band frequencies are 1209, 1336 and 1477 Hz. The
DTMF subroutine assumes that the key decoding is supplied as a low order hex digit in
the accumulator.

24
 If we press 1

The corresponding signal produced

Fig 4) key pad numbers and their signals

3.4.3.3 DTMF DECODER

25
 DTMF decoder is a very easy to use Integrated Circuit to decode DTMF dial
tones found on telephone lines with touch tone phones.
The frequencies used for the DTMF (dual-tone, multi-frequency) system, which
is also referred to as tone dialling are 697, 770, 852, and 941 Hz at low pass filter
and1209, 1336 , 1477 Hz at high pass filter . These frequency signals are encoded as a
pair of sinusoidal (sine wave) tones from the table below which are mixed with each
other. So, we need to decode it for knowing which digit was pressed at the Encoder
.DTMF is used by most PSTN (public switched telephone networks) systems for number
dialing, and is also used for voice-response systems such as telephone banking and
sometimes over private radio networks to provide signaling and transferring of small
amounts of data.
A Decoder need to have many units like High pass filters for Higher frequencies
correspondingly Low pass Filters , and most of the IC have Zero crossing Detector
circuit for Counting the frequency and many other Units . The unit will not detect
numbers dialed using pulse dialing. Circuit uses a CM8870 DTMF receiver chip and pre-
programmed microcontroller.

3.4.3.4 MT8870

The MT8870D/MT8870D-1 is a complete DTMF receiver integrating both the

band split filter and digital decoder functions. The filter section uses switched capacitor
techniques for high and low group filters; the decoder uses digital counting techniques to
detect and decode all 16 DTMF tone pairs into a 4-bit code .And the Latch is used to
hold the output for some time . External component count is minimized by on chip
provision of a differential input amplifier, clock oscillator and latched three-state bus
interface.

26
The PIN Diagram of MT8870

Fig 5) MT8870 IC pin names

The Block Diagram of the MT8870

Fig 6) Functional Block Diagram MT8870 DTMF Decoder

Table No 1) Pin Description

27
28
Fig No 7) Schematic view of mobile interface circuit

Fig. No. 9) Mobile interface circuit on breadboard

29
3.4.3.5 CONSTRUCTION OF MOBILE INTERFACE

Fig No 8) CIRCUIT DIAGRAM OF MOBILE INTERFACE

30
3.4.3.6 DECODING FOR MOBILE INTERFACE:

Table No 2) TABLE SHOWING DTMF LOW AND HIGH FREQUENCY

TONES AND DECODED OUTPUT

3.4.4 PROGRAMMABLE LOGICAL CONTROLLER (PLC)

31
 A programmable logic controller, PLC or programmable controller is a digital
computer used for automation of typically industrial electromechanical processes, such
as control of machinery on factory assembly lines, amusement rides, or light fixtures.
PLCs are used in many industries and machines. PLCs are designed for multiple
analogue and digital inputs and output arrangements, extended temperature ranges,
immunity to electrical noise, and resistance to vibration and impact.
Programs to control machine operation are typically stored in battery-backed-up
or non-volatile memory. A PLC is an example of a "hard" real-timesystem since output
results must be produced in response to input conditions within a limited time, otherwise
unintended operation will result.

Fig 10) PLC used in industries

32
 Fig 11) Block diagram of plc

3.4.4.1 CONSTRUCTION OF PLC

1. Power Supply:- PLCs are generally powered from AC mains and power
supply system converts ac voltages to required dc voltages.
2. Memory:-Program memory receives and holds program instructions. Data
memory is used to temporarily hold data generated from processes or
acquired through I/O devices.
3. Processor:- It is a micro-processor based CPU and is the part of PLC that is
capable of reading and executing program instructions and data.
4. Program loader:- It is used to enter/change the user program into the
memory and to monitor the program execution.

1. Power Supply
 Provides voltage levels required for internal operations (typically+5 V dc or ± 12
V dc).
 Provides power for I/O modules.
 Provides constant voltages.
 Packaged properly to prevent overheat.
 Separate or built into the processing unit.

33
 It is one of the most critical components of a PLC -
1) It is typically non-redundant. Hence a failure of the power supplycan cause the
control system to fail.
2) It usually contains high-voltage components. Hence, an isolationfailure can create
the potential for serious injury and fire.

2. Memory

 The memory function of the CPU stores programs and data that the CPU needs to
perform various operations. The memory is organizedinto several sections according
to the functions they perform.
 Executive Memory - collection of system programs stored inROM.
 Scratch Pad - is the work area used to temporarily store thebinary information
used by the processor. These are volatilememory as RAM-type chips are usually used.
Battery backed-upCMOS RAMs are also used which may last up to 10 years.
 Processor File – The memory block in which programmer storesand manipulates
the software. The processor file is made up ofprogram files, and data files.

3. Central Processing Unit (CPU)

 CPU executes a program stored in the executive memory which isset by the
manufacturer.
 It organizes all control activity by receiving inputs, performinglogical decisions
according to the program, and controls theoutputs.
 CPU does not operate on the I/O directly. Rather, it works with theI/O image
stored in the I/O image memory. The I/O interface isresponsible for transferring the
image outputs to the I/O system,reading the inputs from the I/O system, and writing
them into I/Oimage memory.
 A ‘watchdog’ timer is provided to time the CPU to execute theuser’s program. If
this time exceeds a predetermined value,watchdog timer will indicate fault and
execute subsequentpredefined procedure.

4. Input/ Output (I/O) Systems

 I/O system acts as the eyes, ears and hands of PLCs.
 Discrete I/O - signal is discrete, such as ON/OFF, OPEN/CLOSE,energized/de-
energized etc.

34
 Data I/O - complex system needs data, requires ADC/DAC.
 Input Module functions:
 Reliable signal detection.
 Voltage adjustment of control voltage to logic voltage.
 Protection of sensitive electronics from external voltages.
 Screening of signals.
 Output Modules functions:
 Voltage adjustment of logic voltages to control voltage.
 Protection of sensitive electronics from spurious voltages from
thecontroller.
 Power amplification for actuation of control elements.
 Short-circuit and overload protection of output modules.
 Discrete I/O Inputs - push-buttons, selector switches, joy sticks,relay contacts,
pressure switches, level switches, starter contacts,temperature switches, flow
switches, limit switches, photo-electricswitches, and proximity switches.
 Discrete I/O Outputs - light, relays, solenoids, starters, alarms,valves, heating
elements, and motors.
 Data I/O Inputs - potentiometers, temperature transducers, leveltransducers,
pressure transducers, humidity transducers,encoders, bar code readers, wind speed
transducers.
 Data I/O Outputs - analog meters, digital meters, stepper motors(signals),
variable voltage outputs, and variable current outputs.

5. I/O Capacity
 A factor that determines the size of a programmable controller is thecontroller’s
I/O and capacity.
 Mini-Micro – usually 32 or less I/O, but may have up to 64.
 Small – usually 64 to 128 I/O, but may have up to 256.
 Medium – usually 256 to 512 I/O, but may have up to 1024.
 Large – usually 1024 to 2048 I/O, but may have many thousandsmore on
very large units.
 The I/Os may be directly connected to the PLC or may be in a remote location.
I/Os in a remote location from the processor section can behard wired back to the
controller, multiplexed over a pair of wires, orsent by a fiber optic cable.

3.4.4.2 PLC Programming Languages

 EN 61131-3 defines five PLC programming languages:

35
  Ladder Diagram (LD): graphic language derived from circuitdiagram of
directly wired relay controls.
 Function Block Diagram (FBD): functions & function blocks
arerepresented graphically and interconnected into networks.
 Instruction List (IL): textual assembler-type language consistingof an
operator and an operand.
 Structured Text (ST): high level language based on Pascal.
 Sequential Function Chart (SFC): a language resource for thestructuring
of sequence-oriented control programs.

3.4.4.3 Ladder Diagram (LD)

 The use of ladder programming involves writing a program in amanner to

drawing a switching circuit. The ladder diagramconsists of two vertical lines
representing the power rails, and circuits are connected as horizontal lines.
 Advantages of Ladder Language -
 It is readily understood and maintained.
 It provides graphic display of program flow.
 Programming is fast.
 Generates more readable programs for sequence control.
3.4.4.4 PLC Ladder Programming Conventions
 The vertical lines of the diagram represent the power railsbetween which the
circuits are constructed.
 Each rung on the ladder defines one operation in the controlprocess.
 A LD is read from left to right and from top to bottom.
 Each rung must start with an input or inputs and must end with atleast one output.
Electrical devices are shown in their normal conditions, e.g. anormally closed switch
is shown closed.
 A device can appear in more than one rung of a ladder.
 The inputs and outputs are all identified by their addresses, thenotation used
depending on the PLC manufacturers
3.4.4.5 Necessity of Programming

1. Early PLCs, up to the mid-1990s, were programmed using proprietary

programming panels or special- purpose programming terminals, which often had
dedicated function keys representing the various logical elements of PLC programs.

36
2. Some proprietary programming terminals displayed the elements of PLC
programs as graphic symbols, but plain ASCII character representations of contacts,
coils, and wires were common. Programs were stored on cassette tape cartridges.

3. Facilities for printing and documentation were minimal due to lack of memory
capacity. The very oldest PLCs used non-volatile magnetic core memory.

4. More recently, PLCs are programmed using application software on personal

computers, which now represent the logic in graphic form instead of character
symbols.

5. The computer is connected to the PLC through Ethernet, RS-232, RS-485 orRS-
422 cabling. The programming software allows entry and editing of the ladder-style
logic.

6. Generally the software provides functions for debugging and troubleshooting the
PLC software, for example, by highlighting portions of the logic to show current
status during operation or via simulation.

The software will upload and download the PLC program, for backup and
restoration purposes. In some models of programmable controller, the program is
transferred from a personal computer to the PLC through a programming board which
writes the program into a removable chip such as an EEPROM or EPROM.

3.5 FUNCTIONING OF FLOW CHART:

37
 FLOW CHART

Manual
control
star

input Plc Power Output

contactor timer
control 2

delta
Mobilec
ontrol

Output
1

In the above flow chart shown the motor can be operated by three controlling
methods. After providing the input the controlling of the motor can be first operated by:

1) MANUAL CONTROL: In which we can normally operate the motor by pushing

the forward, reverse and off buttons of our panel for forward, reverse and off action of
motor.

2) PLC CONTROL: In this, we are able to connect the PLC ports which are
provided in the panel to the programming system through which we can operate the
motor.

3) MOBILE INTERFACE: If we want to operate the motor through mobile

interface we can give the signals through mobile and the bluetooth device will catch the
signal through head phones and decode it and will operate the motor as per our
requirement.

38
 In the above mentioned three controlling process after providing the input .We
can choose any one of the above control and after that the process from power contactor
to motor for getting output is same for all . That is after choosing any one control the
supply will go through power contactor then timer will pick up and motor will run in star
and after some time interval in delta. Thus we get the output two. And output one we get
will be directly through power contactor.

39
 Chapter 4
DATA COLLECTION/ TOOLS/
PLATFORMED USED

4. DATA COLLECTION / TOOLS/ PLATFORMED USED

Table No 3) COMPONENTS USED IN PROJECT

SR. NO. COMPONENTS RATING QUANTITY

40
1 Power Contactors:-
a. 12A-MNX12 12A 3
b. 9A-MNX9 9A 1
2. Ammeter (0-15)A 1
3. SP MCB 6A 1
4. Overcurrent relay(4/8) 1
5. Indicators:-
a. Red 2
b. Green 1
c. Yellow 1
6. 3pole MCB 36A 1
7. Push Button:-
a. ON 2
b. OFF 1
8. Power Terminals 6
9. Block:-
a. 2NO2NC 2
b. 1NO1NC 2
10. Timer (0-15) sec 1
11. Control Terminals 12
12. Connectors 6
13. Neutral Link 1
14.a. Wire:- 2.5mm 50ft
b. 1.5mm 150ft
15. Lock Small 2
16. PVC Channel 10
17. MS Channel 5
18. Sleeve:-
a. Red
b. Black
19. Cable Tag Medium 1pac
20. Spiral Small 5ft
21. Nut & Wiser
22. Lug:- 2.5(pin) 1pac.
2.5(U) 1pac.
1.5(Pin) 1pac.
1.5(U) 1pac.
23. Handel:- Small 2
Medium 1
24. Clamp Small 7
25. Wheels Ball type 4
26. Wood Plate
27. End Lock
28. Paint
29. Mobile Kit
30. Black tape
31. Relay 9V 3

41
 4.1 General Information of Main Components.
4.1.1 Miniature circuit breaker(MCB)

The miniature circuit breaker (MCB) actingmain role in providing over

current safety and cut offelectrical networks. MCBs or Miniature Circuit Breakers are
electromechanical devices which protect an electrical circuit from an overcurrent. The
overcurrent, in an electrical circuit, may result from short circuit, overload or faulty
design. An MCB is a better alternative to a Fuse since it does not require replacement
once an overload is detected. Unlike fuse, an MCB can be easily reset and thus offers
improved operational safety and greater convenience without incurring large operating
cost.

Fig.12) Miniature circuit breaker (MCB)

42
 The principal of operation is simple. An MCB functions by interrupting the
continuity of electrical flow through the circuit once a fault is detected. In simple terms
MCB is a switch which automatically turns off when the current flowing through it
passes the maximum allowable limit. Generally MCB are designed to protect against
over current and over temperature faults (over heating).

There are two contacts one is fixed and the other moveable. When the current
exceeds the predefined limit a solenoid forces the moveable contact to open (i.e.,
disconnect from the fixed contact) and the MCB turns off thereby stopping the current to
flow in the circuit. In order to restart the flow of current the MCB is manually turned on.
This mechanism is used to protect from the faults arising due to over current or over
load.

To protect against fault arising due to over heating or increase in temperature a

bi-metallic strip is used. MCBs are generally designed to trip within 2.5 millisecond
when an over current fault arises. In case of temperature rise or over heating it may take
2 seconds to 2 minutes for the MCB to trip.

This article covers the insight of a single pole MCB commonly used in the house
hold. The following image shows the different internal parts of an MCB with top casing
removed. The subsequent sections will examine each part and its function.

a. Single pole MCB (SPMCB):

The standard for circuit breaker panels is either single- or double-pole circuit
breakers. Single-pole breakers are an important part of electrical distributions a safe way
to manage branch circuits from a circuit breaker panel. Single-pole circuit breakers
supply 120-volt power to circuits, while double-pole circuit breakers supply 240-volts to
circuits. Single-pole breakers come in a wide range of amperage ratings, with 15-, 20-,
and 30-amp circuit breakers being the most commonly used in most household
installations. These circuit breakers come in different shapes and sizes, depending upon
the manufacturer of the circuit breaker box. Single-pole breakers supply and protect
120-volt branch circuits from the service panel. They have a handle to manually turn the
circuit breaker both on and off. This handle has a specific amperage labeled on it that is
the maximum amperage allowed to pass through the circuit breaker before it trips.
Single-pole circuit breaker is designed to trip if the amperage rating labeled on the

43
handle is exceeded. This occurs when the circuit is either overloaded or a short circuit
occurs somewhere within the branch circuit that it is connected to. An overload occurs
when too many things or a greater load is connected to any one circuit. A short circuit
occurs when the hot wire is forced to connect to either the neutral or ground wire within
a circuit. It could be a motor winding shorting two wires Single-pole circuit breakers
supply many things throughout the home including general lighting, outlets, furnaces,
electric baseboard heaters, fans, all types of 120-volt appliances, curling irons, hair
dryers, vacuums and many other everyday 120-volt electrical appliances. But the list
doesn’t stop there. They control outdoor lighting, electronic devices, air conditioners,
and those power tools many of you use in garages and out buildings. So you see, single-
pole circuit breakers are a very important part of your overall electrical circuit
protection safety devices and they do their job very well. Many single-pole circuit
breakers have a clear peep sight that shows red when the circuit breaker has tripped. This
along with the handle moving to a center position gives you a clear indication of which
breaker has had trouble on it. The nice thing about circuit breakers is that they can easily
be reset from a tripped state.

b. 3Pole MCB:

When supplying a branch circuit with more than one live conductor, each live
conductor must be protected by a breaker pole. To ensure that all live conductors are
interrupted when any pole trips, a "common trip" breaker must be used. These may either
contain two or three tripping mechanisms within one case, or for small breakers, may
externally tie the poles together via their operating handles. Two-pole common trip
breakers are common on 120/240- volt systems where 240 volt loads (including major
appliances or further distribution boards) span the two live wires. Three-pole common
trip breakers are typically used to supply three-phase electric power to large motors or
further distribution boards. Two- and four-pole breakers are used when there is a need to
disconnect multiple phases AC, or to disconnect the neutral wire to ensure that no current
flows through the neutral wire from other loads connected to the same network when
workers may touch the wires during maintenance. Separate circuit breakers must never
be used for live and neutral, because if the neutral is disconnected while the live
conductor stays connected, a dangerous condition arises: the circuit appears de-energized

44
(appliances don't work), but wires remain live and some RCDs may not trip if someone
touches the live wire (because some RCDs need power to trip). This is why only
common trip breakers must be used when neutral wire switching is needed.

45
 4.1.2 Power Contactor :

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.

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.

46
 Fig. 13) Power Contactor

In addition to 3-pole standard contactors, there are also vacuum contactors,

coupling relays for optimal interfacing with the outputs of controllers, and various
different 4-pole power relays and miniature contactors for the performance range up to 4
kW. The new 3RT2 contactors in sizes S00 and S0 are particularly flexible. Apart from
screw-type connections, the devices are also available throughout with spring-loaded and
ring cable lug connections. The auxiliary switches for S00, S0 and S2 can be installed for
any sizes. An AC/DC version can be controlled using either AC or DC voltage and
simultaneously features much lower holding power of the coils. Two auxiliary switches
are already integrated in the contactors of size S0 and S2 which offer even higher contact
reliability.

1. 12A-MNX12

This contactor has the rating of 12A current. If current exceeded above the 12A
contactor may gets damage. It has 3 ports for input power and 3 for outputs. And there is
one NO port i.e. normally open which is generally used to keep the contactor on after
pressing the switch. There are 2 ports of coil i.e. A1 and A2 which is used to pick-up the
contactor due to that the get the output and the NO gets NC.

47
 2. 9A-MNX9

This contactor has the rating of 9A current. If current

exceeded above the 9A contactor may gets damage. It has 3
ports for input power and 3 for outputs. And there is one
NO port i.e. normally open which is generally used to keep
the contactor on after pressing the switch. There are 2 ports of
coil i.e. A1 and A2 which is used to pick-up the contactor due to
that the get the output and the NO gets NC.

4.1.3 Add on Blocks:

1. 2NO2NC:-

It is the additional NO and NC blocks which is mounted

on the power contactor. When power contactor gets pick-up
same time the NO and NC switch gets pick-up. In this block
there are 2NO and 2NC switches. This all operation is
mechanically performed; it does not require any power supply.
When power contactor gets pick-up all NO gets NC and NC
gets NO.

2. 1NO1NC

48
 It is the additional NO and NC blocks which is
mounted on the power contactor. When power contactor
gets pick-up same time the NO and NC switch gets pick-
up. In this block there are 1NO and 1NC switches. This
all operation is mechanically performed; it does not
require any power supply. When power contactor gets
pick-up all NO gets NC and NC gets NO.

4.1.4 Over current relay(4/8):

A relay is an electrically operated switch. Many relays use an electromagnet to

mechanically operate a switch, but other operating principles are also used, such as solid-
state relays. 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.

1. Working Principle of Over Current Relay

In an over current relay, there would be essentially a current coil. When normal
current flows through this coil, the magnetic effect generated by the coil is not sufficient
to move the moving element of the relay, as in this condition the restraining force is
greater than deflecting force. But when the current through the coil increased, the
magnetic effect increases, and after certain level of current, the deflecting force
generated by the magnetic effect of the coil, crosses the restraining force, as a result, the
moving element starts moving to change the contact position in the relay.

Although there are different types of over current relays but basic working
principle of over current relay is more or less same for all.

2. Types of Over Current Relay

Depending upon time of operation, there are various types of OC relays, such as,

1. Instantaneous over current relay.

49
 2. Definite time over current relay.

3. Inverse time over current relay.

Instantaneous Over Current Relay

Construction and working principle of instantaneous over current relay quite simple.
current relay” width=”640″
height=”485″ class=”align center size-
full wp-image-11661″ />
Here generally a magnetic core is
wound by current coil. A piece of iron
is so fitted by hinge support and
restraining spring in the relay, that
when there is not sufficient current in
the coil, the NO contacts remain open. When current in the coil crosses a present value,
the attractive force becomes sufficient to pull the iron piece towards the magnetic core
and consequently the No contacts are closed.

The preset value of current in the relay coil is referred as pick up setting current.
This relay is referred as instantaneous over current relay, as ideally, the relay operates as
soon as the current in the coil gets higher than pick up setting current. There is no
intentional time delay applied. But there is always an inherent time delay which can not
be avoided practically. In practice the operating time of an instantaneous relay is of the
order of a few milliseconds.

3. Definite Time Over Current Relay

This relay is created by applying intentional time delay after crossing pick up
value of the current. A definite time over current relay can be adjusted to issue a trip
output at definite amount of time after it picks up. Thus, it has a time setting adjustment
and pick up adjustment.

4. Inverse Time OC Relay

Inverse time is a natural character of any induction type rotating device. This
means the speed of rotation of rotating art of the device is faster if input current is
increased. In other words, time of operation inversely varies with input current. This

50
natural characteristic of electromechanical induction disc relay in very suitable for over
current protection. This is because, in this relay, if fault is more severe, it would be
cleared more faster. Although time inverse characteristic is inherent to electromechanical
induction disc relay, but the same characteristic can be achieved in microprocessor based
relay also by proper programming.

5. Inverse Definite Minimum Time Over Current Relay or IDMT O/C

Relay

Ideal inverse time characteristics cannot be achieved, in an over current relay. As

the current in the system increases, the secondary current of the current transformer is
increased proportionally. The secondary current is fed to the relay current coil. But when
the CT becomes saturated, there would not be further proportional increase of CT
secondary current with increased system current.

From this phenomenon it is clear that from trick value to certain range of faulty
level, an inverse time relay shows exact inverse characteristic. But after this level of
fault, the CT becomes saturated and relay current does not increase further with
increasing faulty level of the system. As the relay current is not increased further, there
would not be any further reduction in time of operation in the relay. This time is referred
as minimum time of operation.

Hence, the characteristic is inverse in the initial part, which tends to a definite
minimum operating time as the current becomes very high. That is why the relay is
referred as inverse definite minimum time over current relay or simply IDMT relay.

4.1.5 Ammeter

An ammeter is a measuring instrument used to measure the electric current in a

circuit. Electric currents are measured in amperes (A), hence the name. Instruments used
to measure smaller currents, in the milliampere or microampere range, are designated as
milliammeters or microammeters.

When PMMC is used as an ammeter, except for a very small current range, the
moving coil is connected across a suitable low resistance shunt, so that only small part of
the main current flows through the coil. The shunt consists of a number of thin plates

51
made up of alloy metal, which is usually magnetic and has a low temperature coefficient
of resistance, fixed between two massive blocks of copper. A resistor of same alloy is
also placed in series with the coil to reduce errors due to temperature variation.

Fig 14) Ammeter

The majority of ammeters are either connected in series with the circuit carrying
the current to be measured (for small fractional amperes), or have their shunt resistors
connected similarly in series. In either case, the current passes through the meter or
(mostly) through its shunt. Ammeters must not be connected directly across a voltage
source since their internal resistance is very low and excess current would flow.
Ammeters are designed for a low voltage drop across their terminals, much less than one
volt; the extra circuit losses produced by the ammeter are called its "burden" on the
measured circuit.

Since the ammeter shunt has a very low resistance, mistakenly wiring the
ammeter in parallel with a voltage source will cause a short circuit, at best blowing a
fuse, possibly damaging the instrument and wiring, and exposing an observer to injury.

4.1.6 Timer

Some relays are constructed with a kind of "shock absorber" mechanism attached
to the armature which prevents immediate, full motion when the coil is either energized
or de-energized. This addition gives the relay the property of time-delay actuation. Time-
delay relays can be constructed to delay armature motion on coil energization, de-
energization, or both.

52
 Time-delay relay contacts must be specified not only as either normally-open or
normally-closed, but whether the delay operates in the direction of closing or in the
direction of opening. The following is a description of the four basic types of time-delay
relay contacts.

First we have the normally-open, timed-closed (NOTC) contact. This type of

contact is normally open when the coil is unpowered (de-energized). The contact is
closed by the application of power to the relay coil, but only after the coil has been
continuously powered for the specified amount of time. In other words, the direction of
the contact's motion (either to close or to open) is identical to a regular NO contact, but
there is a delay in closing direction. Because the delay occurs in the direction of coil
energization, this type of contact is alternatively known as a normally-open, on-delay:

The following is a timing diagram of this relay contact's operation:

Next we have the normally-open, timed-open (NOTO) contact. Like the NOTC
contact, this type of contact is normally open when the coil is unpowered (de-energized),
and closed by the application of power to the relay coil. However, unlike the NOTC
contact, the timing action occurs upon de-energization of the coil rather than upon
energization. Because the delay occurs in the direction of coil de-energization, this type
of contact is alternatively known as a normally-open, off-delay:

53
The following is a timing diagram of this relay contact's operation:

Next we have the normally-closed, timed-open (NCTO) contact. This type of

contact is normally closed when the coil is unpowered (de-energized). The contact is
opened with the application of power to the relay coil, but only after the coil has been
continuously powered for the specified amount of time. In other words, the direction of
the contact's motion (either to close or to open) is identical to a regular NC contact, but
there is a delay in the opening direction. Because the delay occurs in the direction of coil
energization, this type of contact is alternatively known as a normally-closed, on-delay:

The following is a timing diagram of this relay contact's operation:

54
 Finally we have the normally-closed,
timed-closed (NCTC) contact. Like
the NCTO contact, this type of
contact is normally closed when the
coil is unpowered (de-energized), and
opened by the application of power to
the relay coil. However, unlike the NCTO contact, the timing action occurs upon de-
energization of the coil rather than upon energization. Because the delay occurs in the
direction of coil de-energization, this type of contact is alternatively known as a
normally-closed, off-delay:

The following is a timing diagram of this relay contact's operation:

Time-delay relays are very important for use in industrial control logic circuits.
Some examples of their use include:

 Flashing light control (time on, time off): two time-delay relays are used in
conjunction with one another to provide a constant-frequency on/off pulsing of
contacts for sending intermittent power to a lamp.

 Engine autostart control: Engines that are used to power emergency generators
are often equipped with "autostart" controls that allow for automatic start-up if the
main electric power fails. To properly start a large engine, certain auxiliary devices

55
 must be started first and allowed some brief time to stabilize (fuel pumps, pre-
lubrication oil pumps) before the engine's starter motor is energized. Time-delay
relays help sequence these events for proper start-up of the engine.

 Furnace safety purge control: Before a combustion-type furnace can be safely lit,
the air fan must be run for a specified amount of time to "purge" the furnace chamber
of any potentially flammable or explosive vapors. A time-delay relay provides the
furnace control logic with this necessary time element.

 Motor soft-start delay control: Instead of starting large electric motors by

switching full power from a dead stop condition, reduced voltage can be switched for
a "softer" start and less inrush current. After a prescribed time delay (provided by a
time-delay relay), full power is applied.

 Conveyor belt sequence delay: when multiple conveyor belts are arranged to
transport material, the conveyor belts must be started in reverse sequence (the last one
first and the first one last) so that material doesn't get piled on to a stopped or slow-
moving conveyor. In order to get large belts up to full speed, some time may be
needed (especially if soft-start motor controls are used). For this reason, there is
usually a time-delay circuit arranged on each conveyor to give it adequate time to
attain full belt speed before the next conveyor belt feeding it is started.

The older, mechanical time-delay relays used pneumatic dashpots or fluid-filled

piston/cylinder arrangements to provide the "shock absorbing" needed to delay the
motion of the armature. Newer designs of time-delay relays use electronic circuits with
resistor-capacitor (RC) networks to generate a time delay, then energize a normal
(instantaneous) electromechanical relay coil with the electronic circuit's output. The
electronic-timer relays are more versatile than the older, mechanical models, and less
prone to failure. Many models provide advanced timer features such as "one-shot" (one
measured output pulse for every transition of the input from de-energized to energized),
"recycle" (repeated on/off output cycles for as long as the input connection is energized)
and "watchdog" (changes state if the input signal does not repeatedly cycle on and off).

56
 The "watchdog" timer is especially useful for monitoring of computer systems. If
a computer is being used to control a critical process, it is usually recommended to have
an automatic alarm to detect computer "lockup" (an abnormal halting of program
execution due to any number of causes). An easy way to set up such a monitoring system
is to have the computer regularly energize and de-energize the coil of a watchdog timer
relay (similar to the output of the "recycle" timer). If the computer execution halts for
any reason, the signal it outputs to the watchdog relay coil will stop cycling and freeze in
one or the other state. A short time thereafter, the watchdog relay will "time out" and
signal a problem.

4.1.7 RELAYS

57
 A relay is an electrically operated switch. Relays are used where it is necessary to
control a circuit by a low-power signal with complete electrical isolation between control
and controlled circuit.

LOW
POWER HIGH POWER CIRCUIT
Input RELAY

Fig 15) Relays

1. SOLID STATE RELAYS

A solid-state relay is an ON-OFF control device in which the load current is

conducted by one or more semiconductors - e.g., a power transistor, an SCR, or a
TRIAC. (The SCR and TRIAC are often called “thyristors,” a term derived by
combining thyratron and transistor, since thyristors are triggered semiconductor
switches.)

Like all relays, the SSR requires relatively low control circuit energy to switch the output
state from OFF to ON, or vice versa. Since this control energy is very much lower than
the output power controllable by the relay at full load, "power gain" in an SSR is
substantial--frequently much higher than in an electromagnetic relay of comparable
output rating. To put it another way, the sensitivity of an SSR is often significantly higher
than that of an EMR of comparable output rating.

Photo-coupled SSR's (see figure 3), in which the control signal is applied to a light or
infrared source (usually, a light-emitting diode, or LED), and the radiation from that
source is detected in a photosensitive semi-conductor (i.e., a photosensitive diode, a

58
photo-sensitive transistor, or a photo-sensitive thyristor). The output of the photo-
sensitive device is then used to trigger (gate) the TRIAC or the SCR's that switch the
load current. Clearly, the only significant “coupling path” between input and output is the
beam of light or infrared radiation, and electrical isolation is excellent. These SSR's are
also referred to as “optically coupled” or “photo-isolated”.

2. REVIEW:

 Time delay relays are built in these four basic modes of contact operation:

 1: Normally-open, timed-closed. Abbreviated "NOTC", these relays open

immediately upon coil de-energization and close only if the coil is continuously
energized for the time duration period. Also called normally-open, on-delay relays.

 2: Normally-open, timed-open. Abbreviated "NOTO", these relays close

immediately upon coil energization and open after the coil has been de-energized for
the time duration period. Also called normally-open, off delay relays.

 3: Normally-closed, timed-open. Abbreviated "NCTO", these relays close

immediately upon coil de-energization and open only if the coil is continuously
energized for the time duration period. Also called normally-closed, on-delay relays.

 4: Normally-closed, timed-closed. Abbreviated "NCTC", these relays open

immediately upon coil energization and close after the coil has been de-energized for
the time duration period. Also called normally-closed, off delay relays.

 One-shot timers provide a single contact pulse of specified duration for each coil
energization (transition from coil off to coil on).

 Recycle timers provide a repeating sequence of on-off contact pulses as long as

the coil is maintained in an energized state.

 Watchdog timers actuate their contacts only if the coil fails to be continuously
sequenced on and off (energized and de-energized) at a minimum frequency.

4.1.8 Neutral link

In 3phase ac system ,In the case of link in neutral, we should not use fuse(neutral
is using at distribution level for getting single phase or 3 phase 3wire 4wire system to

59
supply the power to the some loads). Suppose we use the fuse in the neutral line, if any
fault or break occur in the neutral line, but current flows from phase/line to load and
come to neutral wire where it has break, there will be a chance to shock to human
beings/workers who will do the works regarding the repairs. We generally putting fuse in
phase/line for protecting the equipment/device from high voltages/currents. If any fault
occur in the phase/line,current will not flows from fuse, only it will come fuse hence
there is no problem. But in the case of neutral, the current flows through out equipment
that may lead to create some problems as mentioned above. That's why we should put
only link for neutral in three phase ac system.

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 Chapter 5
DESIGN/
IMPLEMENTATION

5. DESIGN/IMPLEMENTATION

5.1 Drilling on the door

First we select the wooden box as required
dimension. We select the wooden box because it is bad
conductor of electricity and it is cheaper than coated steel
frame. After that we made seven holes on the door frame for
four indicators and three buttons. The first is red indicator
for forward on. The second is also red indicator for reverse
on. The third is green indicator which shows off indication.
The last is yellow indicator which shows trip indication.

61
And the first green button is for the forward on operation. The second green button is for
the reverse on operation. The third red button is for the off operation. We made a square
cut on the door for ammeter mounting, So that we can see the current rating of the motor.

5.2Mounting of door
After that we mounted the wooden door on the whole
frame, with the help of three clamps. Then we adjust the
door so that it should move properly. It should be noted that
door always set free so that it will be operate easily and it
should be user friendly. The door should have the locking
arrangement so that the illiterate person can’t get inside so
that accident can be avoided.

5.3 Painting
The attraction of the panel is also important
parameter from user point of view. Which include the
painting, inner proper arrangement of component and
wiring. So we painted our panel from all side which make
our panel more attractive and beautiful. We used the primer
for the painting, because it is good with the wooden frame.

5.4 Mounting of the indicators

After the painting when the paint is gets dry

we started mounting of components on the
wooden door. First we mount the indicators. Here we
can see the all indicators mounted on the door. The
all indicators have the name plates of each operation.
Like reveres on, forward on, off and trip indication, similarly
the forward on, reverse on and off buttons. There is one
ammeter mounted on the door. This ammeter have rating of 15 A.

62
 5.5 Assembly of components

Then we started the mounting of main components on

the back frame of the panel. First we mounted the PVC
channels for holding of wires. After that we mounted the
steel channel, because all components are mounted on steel
channel. After that we mounted the 3 pole MCB on the
channel, then DP MCB, timer, power contactors of different
ratings with the overload relay. We can see the arrangements of components on the panel.
It should be noted that the mounting of channels and contactors should be with standard
measurement. This makes the panel more
attractive

5.6 Control wiring and Power wiring

Then we proceeded toward the wiring scheme of

the panel. Then we started with the power wiring.
Because the wire used for power circuit should be
high rating. We used here wire of 2.5 mm sq. The
power wiring is done for all three phase. Then we
proceeded to the control wiring. We used 1.5 mm
sq. multi strand wire for control circuit. When we completed the control wiring, then we
put all wire in the PVC channel. So that panel looks attractive. One thing should be noted
that all wiring done with the help of diagram, and should be check and tested.

5.7 Mounting of plate in the panel

In last we mounted the back plate to the panel as

we can see in the fig. After that we covered the PVC
channel so that all wire can be safe and hidden. Then we
proceeded to the door termination, where we wired the

63
indicators and buttons. We used spirals to mount the other bunch of wires. So we got our
overall panel as shown in the figure.

Chapter
64 6
TESTING AND SUMMARY
 6. Testing and summary of result
6.1 Testing of components

In starting, when we purchased the components, we didn’t get that by testing

from the shopkeeper. So after purchasing the component our first priority was to test the
components whether they are working properly or not. So we tested all the power
contactors, all MCBs, timer and the over current relay. Because for proper working of
panel, all component should be work correctly otherwise many dangerous accident can
takes place. So we found our all components are working properly.

6.2 Testing of power and control circuit

when we completed the all work of our panel, we wanted to test the panel so that
we can see whether our panel working as we expected or not. Then we first provided

65
supply only to the control circuit so that we can see the panel can be control as we
designed it. At that time, we didn’t provide the 3 phase supply to the power circuit
because any mistake could damage the components and panel as well. That’s why we
checked the control circuit first. We checked that all contactors are working as we
wanted to. Means we checked when we push the forward button, the first
contactorshould be get pick-up along with the star contactor and after some time star
contactor get to off and delta contactor gets on. And at the same time, reverse button
can’t be operated otherwise the phase can be short circuited to each other. Similarly we
tested for the reverse button. After that we tested the circuit can isolate the supply when
over current is occur by tripping the over current relay.

When we saw that our control circuit is operating properly, we wanted to test the
power circuit as well. So we provide the three phase supply to the panel, then we
operated the panel for forward direction and we tested that we got the 3 phases at the
output power terminals. Similarly we tested for the reverse operation and we got the
expected result. In last, we connected a 3 phase, 6 terminal, induction motor of 5 hp
motor and we checked that all operations like reverse and forward are performed
successfully, All components, indicators and buttons are working properly.

6.3 Testing of mobile interface circuit and interface with panel

The main problem with the mobile interface circuit is to operate the relay set with
the help of mobile. And also, one more problem is to operate a specific relay from relay
set by using mobile interface circuit. So we performed many operations to check, by
which button of mobile which relay is operating. According to that we decided to used
the relays to perform the forward, reverse and off operation. Then we interfaced this
circuit to the panel. After that we again tested the control circuit only with the help of
mobile keypad and we found that our circuit working properly. Then we tried the mobile
interface circuit with power circuit on and motor connected with it. We successfully
achieved our aim that is to perform reverse forward operation with star delta starter using
the mobile phone from anywhere.

66
SUMMARY OF RESULT

 We got good practical knowledge which needs to make a panel.

 We made our project more attractive and user friendly.

 We achieved our aim which is to operate the motor in forward and reverse
direction.

 Our panel provide good protection from high starting current as we used star
delta starter and from overload and mishandling of panel.

 Our panel can operate with the help of mobile phone.

 The panel can be operated from anywhere with the help of mobile interface
circuit.

 By knowing the future’s need, we leave some future interlock port so that our
panel can be operate or interface by any system like PLCs and SCADA.

 So we can say that we have done over project successfully and our panel
overcomes problems which is arises like control of panel with the help of mobile from
anywhere.

CONCLUSION:

We can say that the problem which was arises, are successfully overcome in our
project. We made our project very attractive and user friendly, so that it can be operated
by anyone. And we had provided interlocking in our panel so that if motor is running in
forward direction and if we push reverse button then it will not going to operate in
reverse mode because of interlocking and same if motor is running in reverse direction it
will not going to operate in forward mode.We got more practical knowledge of panel
construction and panel erection. We had also given our project for patent filling.

67
68
 Chapter 7
REFERENCES

7. Reference
7.1 For Reverse forward drive with star delta starter:
 FORWARD -REVERSE SELECTOR WITH STARTER SWITCH Filed
March 27, 1970 V "W BNTOIS I CARL IVAR BENSON, JR. JAMES (NM!)
RAPOZA ATTORNEYS United States Patent 3,6l3,482 Patented Oct. 19,
1971,613,482 FGRWARD-REVERSE SELECTOR WITH STARTER
SWITCH Carl Ivar Benson, Jr., Westwood, and James Rapoza,
 Published in: Industry Applications, IEEE Transactions on (Volume:32 ,
Issue: 2 )
 Page(s):393 - 402
 ISSN :0093-9994

69
  INSPEC Accession Number:5245094
 DOI:10.1109/28.491489
o Date of Current Version :06 August 2002
o Issue Date :Mar/Apr 1996
o Sponsored by IEEE Industry Applications Society
o Publisher: IEEE
7.2 For Mobile Interface:

ITU-T Recommendation Q.2220, Transport Independent Signalling Connection

Control Part (TI-SCCP).

7.3 For PLC Interface:

 E. A. Parr, Industrial Control Handbook, Industrial Press Inc., 1999 ISBN 0-

8311-3085-7
 M. A. Laughton, D. J. Warne (ed), Electrical Engineer's Reference book, 16th
edition,Newnes, 2003 Chapter 16Programmable Controller
 "The father of invention: Dick Morley looks back on the 40th anniversary of the
PLC". Manufacturing Automation. 12 September 2008.
A. Harms, Toni M. &Kinner, Russell H. P.E., Enhancing PLC Performance with
Vision Systems. 18th Annual ESD/HMI International Programmable Controllers
Conference Proceedings, 1989, p. 387-399.

70