Click and visit [Link].

in for All Books & Courses

INDEX
Chapter Syllabus Description Page No
❖ Basic of Electrical
1. Electrical Basic Concept 09
What is AC Supply, Single Phase AC Supply, Three Phase Power Supply 10
What is DC Supply, what is Voltage, what is AC Current 12
2. Why use √3 in 3 Phase system, what is 120 Degree 15
3. Electrical Thumb Rules 16
4. Useful Measuring Unit 17
5. Electrical unit conversation 18
6. Electrical Symbols 20
7. PVC Flexible Copper Wire/Cable Amp Current capacity 26
8. Electrical formulas 27
9. Earthing Wire Size for house wiring and Motor 28
Chapter Syllabus Description Page No
❖ House wiring and home appliances
10. Electrical Reference for Copper Wire/Cable Current 29
11. MCB Rating and Class Selection 33
12. House Appliances According to MCB Class 34
13. How to select MCB for house wiring and 37
14. What are the ELCB/RCCB, RCBO, MCCB, AFDD/AFCI Breakers 41
15. Single phase meter’s connection with 3 Phase meter 49
16. VMR relay connection (Voltage monitoring relay) 50
17. What is the series board for electricians & how to use 52
18. Surge protection device (SPD) 54
19. House wiring 56
20. House wiring with Inverter connection 68
21. How do you fit the inverter with the existing house/room wiring? 71
22. How to select Battery and Inverter for home 72
23. Geyser connection 73
24. Geyser fault and rectification 74
25. The ceiling fan Connection 76
26. The ceiling fan wiring with the regulator 79
27. Staircase wiring with 2-Way Switch 80
28. The doorbell switch wiring 81
29. Fridge connection single-door & double-door 82
30. Washing machine connection 84
31. Submersible automatic starter (Water Tank fills automatically) 86
❖ Basic of All Electrical appliances
32. What is the Ammeter & Voltmeter & how to use 87
33. What are NO and NC Button & how to use 89
34. What is Contactor & how to use 90
Chapter Syllabus Description Page No
35. What is a Capacitor Contactor & how to use 91
36. What is an Auxiliary Contactor & how to use 92
37. What is the selector Switch and How to use 93
38. What is a Float switch & how to use 94
39. Float switch connection 95
40. What is OLR (Overload relay) 96
41. What is MPCB (Motor Protection Circuit Breaker) 97
42. What is Interlocking 99
43. What is an Analog and digital timer & how to use 100
❖ Basics of starters
44. What is a Starter 102
45. Different Types of the Starter 103
46. Star Connection Wiring 105
47. Delta Connection Wiring 107
48. How to Select OLR Relay for DOL Starter 109
49. How to Select OLR Relay for Star Delta Starter 110
50. How to Select Contactor for DOL Motor Starter 112
51. How to Select Contactor for Star Delta Motor Starter 113
52. How to Select the Right Circuit Breaker for Motor Starter 115
53. How to select wire Size for Motor starter 116
54. How to read Electrical drawing 117
❖ Single Phase Starter
55. Single Phase Starter with One Capacitor & With One Way Switch Single 121
line diagram
56. Single Phase Starter with One Capacitor & With One Way Switch – 3D 123
View
57. Single Phase starter with Double Capacitor & With Contactor – 3D View 124
Chapter Syllabus Description Page No
58. Single Phase MK1 starter (Double Capacitor) – 3D View 125

59. Single Phase Motor Capacitor Connection & Control with Plug 126
Top/MCB
❖ Direct On-Line Starter (DOL)
60. DOL Starter Working Principle 127

61. DOL Power Wiring Diagram & Power Wiring- 3D View 129

62. DOL Single line Control wiring 3 Phase 415 Volt 130

63. DOL Control wiring -3D View 3 Phase 415 Volt 131

64. DOL Single line Control wiring 1 Phase 230 Volt 132

65. DOL Control wiring -3D View 1 Phase 230 Volt 133

❖ Direct On-Line Starter with Indicator

66. DOL Starter Single line diagram with indicator Single line diagram 135

67. DOL Starter Control wiring with indicator - 3D View 136

68. Automatic Water Level Controller 137

❖ Direct On-Line Starter Local & Remote wiring

69. DOL Starter Single line diagram Remote wiring from 2 Places 138

70. DOL Starter Remote wiring from 2 Places - 3D View 140

71. DOL Starter Singal line diagram Remote wiring from 3 Places 141

72. DOL Starter Remote wiring from 3 Places - 3D View 142

❖ Direct On-Line Starter with Float switch

73. DOL Starter Singal line diagram with float switch With Selector Switch 143

74. DOL Starter diagram with float switch With Selector Switch- 3D View 146

❖ Direct On-Line Reverse Forward Starter

75. DOL Starter Reverse Forward Single Line Power diagram 147
Chapter Syllabus Description Page No
76. DOL Starter Reverse Forward Power diagram -3D View 148

77. DOL Starter Power Wiring Diagram & Key Diagram with Digital Timer 149

❖ Star Delta Starter

78. Star Delta Starter Power Wiring Single Line Diagram 154

79. Star Delta Starter Power wiring -3D View 155

80. Star Delta Starter Control wiring single line diagram 155

81. Star Delta Starter Power & Control wiring -3D View 156

82. Star Delta Starter single-line diagram with Indicator 156

83. Star Delta Starter Power & Control Wiring With indicator-3D View 157

84. Star Delta Starter without Timer Single Line Diagram 157

85. Star Delta Starter without Timer-3D View 158

86. Star Delta Starter without Timer Single Line Diagram with indicator 158

87. Star Delta Starter without Timer with Indicator- 3D View 159

❖ Star Delta Starter Remote Wiring

88. Star Delta Starter Control from 2 Places Singal Line Diagram 160

89. Star Delta Starter Control from 2 Places -3D View 161

❖ Star Delta Starter Reverse Forward

90. Star Delta Reverse Forward Starter Power Wiring Single Line Diagram 162

91. Star Delta Reverse Forward Starter Power Wiring - 3D View 163

92. Star Delta Reverse Forward Control Wiring Single Line Diagram 164

93. Star Delta Reverse Forward Control Diagram- 3D View 164

94. Star Delta Reverse Forward Control Wiring with indicator Single Line 165
Diagram
95. Star Delta Reverse Forward Control Wiring with indicator - 3D View 165
Chapter Syllabus Description Page No

❖ Soft Starter
96. Soft Starter working principle, how to use Soft Starter 166

❖ VFD Starter
97. Variable frequency drive (VFD) working principle 167

98. VFD Remote wiring with push button 179

99. VFD wiring with Limit Switch in conveyor 170

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may result in criminal penalties. - The author Gaurav Yadav

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Last eBook Update: 13-12-2024, 165+ pages

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 Welcome to Tech Gaurav eBook

1. Electrical Basic Concept:

What is AC Supply?
In Alternating Current (AC), the flow of electricity changes direction periodically.
It is the most used type of electricity in homes, offices, and buildings. AC is
recognized by its waveform, known as a "sine wave."

Simply put, it can be visualized as a curved line. These curves represent electrical
cycles, and their frequency is measured in "Hertz" (Hz), which tells how many
cycles occur per second.
Single-Phase Power Supply:

A single-phase power supply has two main wires: a phase wire and a neutral
wire. The AC supply from the transformer reaches the load through the phase
wire. After passing through the load, the current returns to the source via the
neutral wire.

Single-phase power supply is used for electrical devices and appliances that
require less power. It is commonly used to power fans, coolers, small air
conditioners, lamps, and other household appliances.

However, single-phase power supply is not suitable for powering large industrial
equipment.
Three-Phase Power Supply:
A three-phase power supply typically has three current-carrying conductors
(wires). The circuit configuration can be either Star or Delta.

• Star Configuration: This setup includes an additional neutral wire. In this

configuration, all three phases are connected at a common point, called
the "neutral point."

• Delta Configuration: This setup does not have a neutral wire. Instead, the
phases are connected in a triangular (delta) shape. This configuration is
efficient for powering large industrial equipment.

Three-phase power supply is commonly used in industries and for heavy-load

equipment because it provides high-capacity and more stable electricity
compared to single-phase systems.

A three-phase power system can be understood through three sine waves, each representing
one conductor (wire). These sine waves are spaced 120° apart, creating a phase difference.

This phase difference ensures a continuous and balanced flow of electricity, making the three-
phase system ideal for powering large equipment and factories.
What is DC Supply?
A DC power supply is a device that provides Direct Current (DC) to a load. In Direct Current,
the flow of electricity is always in one direction and does not reverse.
Due to this steady flow, DC power is essential for operating electronic devices, toys, and
various other equipment.
What is voltage?
Voltage is the force that comes from an electrical circuit's power source, helping electrons
(current) flow through wires to perform tasks like lighting a bulb.
In simple terms, voltage = pressure, and it is measured in volts (V).
What is current?

Current is the flow of electricity where charged electrons move through a conductor, like
a wire. In simpler terms, current is what makes electricity "run" through a circuit, enabling
devices to work. For example, when you turn on a fan, the current flows to it and makes it
operate.
Key Points:
• Current is measured in Amperes (A).
• It is measured using a device called an Ammeter.
Types of Current:
1. Direct Current (DC): The flow of charge is in a single direction, like the current from a
battery.
2. Alternating Current (AC): The flow of charge changes direction periodically, like the
electricity in homes.
2. Why use √3 in 3 Phase system, what is 120 Degree

In a three-phase power system, there is a relationship between line voltage

(voltage between two wires) and phase voltage (voltage between a single wire
and neutral). This relationship involves √3. Here's the simple formula:
Line Voltage = √3 × Phase Voltage
Understanding this concept might seem a bit tricky, so I’ve made a simple and
easy-to-follow video in Hindi for you. Click on the link or scan the QR code below
to watch the video and understand it effortlessly!
 3. Electrical Thumb Rules:

For Copper Wire Current Capacity 6X Size of Wire in [Link]

(Up to 30 [Link]) Example
2.5 [Link]= 6x2.5=15 A
1 [Link]= 6x1=6 A
1.5 [Link]=6x1.5=9 A
For Copper Wire Cable Current Capacity 4X Size of Cable in [Link],
Example
2.5 [Link]= 4x2.5=10 Amp

KW Rating of Motor =HPx0.75

Full Load Current of 1 Phase Motor =HPx6
Full Load Current of 3-Phase Motor =HPx1.5
1 Phase Motor draws Current =6 Amp/HP.
3 Phase Motor draws Curren =1.25 Amp/HP.
Earthing Resistance = Single Pit =5Ω, Earthing Grid=0.5Ω
Voltage between Neutral and Earth <=2 Volts
The resistance between Neutral and <=1Ω
Earth

No Load Current of 3-Phase Motor =30% of FLC

Current Rating of Transformer =KVAx1.4
No Load Current of Transformer Lesh then 2 % of Transformer Rated current
Approximate Current =1.39xKVA (for 3 Phase 415Volt)
Approximate Current =1.74xKW (for 3 Phase 415Volt)
4. Useful Measuring Unit:

1HP=0.746KW 1Foot=30.48 cm 1Tone= 3530 BTU

1KW=1.36HP 1Foot=12 inch 1Tone= 12000 BTU/Hr
1inch= 2.54 cm 1Tone= 3.5 KW

1Meter= 39.3 Inch 85 Sq. ft Floor

Area=1200 BTU
1Yard=3 feet

1Yard=36 inch

1Gaj=36 inch
5. Electrical Unit Conversions:
6. Electrical Symbols:
NO
\O

NC
Friends, if I display all the symbols here, it will take up many pages. Therefore, I
request you to download my Tech Gaurav app or visit my website
[Link]. From there, you can access the Symbols Book for free. This
book has more than 35 pages, and I am offering it to you completely free of cost!
7. Copper Wire/Cable Amp Capacity

Sq. mm Amp Sq. mm Amp

0.5 4 10 46
0.75 7 16 62
1.0 11 25 80
1.5 15 35 102
2.5 19 50 138
4.0 26 70 214
6.0 35 95 254
10 46 120 300
8. Electrical Formulas:
These are the Basic Electrical Formulas followed by Ohm's Law. The variables used in these
formulas are as follows:

V = Voltage in Volts

I = Current in Amperes

R = Resistance in Ohms

P = Power in Watts
9. Earthing Wire Size for house wiring and Motor

Friends, Earth is the largest conductor in the world. That's why we ground any
electrical device. Grounding is also known as earthing. It helps protect against
electric shocks. Earthing ensures compliance with safety standards in electrical
devices.
10. Electrical Reference for Copper & Aluminium wire/Cable
Current:

• Single Core
• Double Core
• Three Core
• 3.5 Core

Standard Voltage Limit:

11. House Appliances According to MCB Class

MCB Class according to Appliances

Appliance Capacity / watt MCB Rating MCB Class
1.0 Tone 10A C Class
Air Conditioner 1.5 Tone 16A C Class
2.0 Tone 20A C Class
165 Liter 3A C Class
Freeze
350 liter 4A C Class
300Watt 2A C Class
Washing Machine
1300Watt 8A C Class
1000Watt 6A B Class
Room Heater
2000Watt 10A B Class
750Watt 6A B Class
Iron
1250Watt 8A B Class
1200Watt 8A B Class
Toster
1500Watt 10A B Class
1000Watt 6A B Class
2000Watt 10A B Class
Water Heater
3000Watt 16A B Class

6000Watt 32A B Class

12. MCB Rating and Class Selection:

• B Type:
• C Type:

• D Type:
• K Type:

• Z Type
13. How to select MCB for House wiring
Friends, generally for domestic purposes we use Type-B and Type-C MCB.
Type B
It can be used in most home appliances. Like can be used for lights, bulbs,
Switchboards, fans, TVs, room heaters, irons, toasters, water heaters, etc.
Type C
It can be used in most home appliances like submersible Starter, tullu pumps,
air conditioners, fridges, washing machines, stabilizers, printers, etc.
MCB:
MCB stands for "Miniature Circuit Breaker", and is an electrical device used to
protect electrical operations. MCB is installed in the electrical panel, and it
protects the power line from fault, overcurrent, and other malfunctions. The
main purpose of MCB is to switch off the power supply when there is any fault
or signal in the electrical operation, thereby ensuring the safety of electrical
operation.

MCBs are used in homes, commercial places, and industrial sites to ensure
protection against surges and surges that occur during electrical operations. If
there is an overcurrent in any power line, the MCB switches it off immediately,
thereby shutting off the power immediately and ensuring safety that no damage
occurs.
Why does MCB trip again and again?

There can be two to three possibilities, either one of the neutral or phase wires
has melted due to excessive load on the joint and somewhere the phase or
neutral wires are touching each other. If the wire starts heating due to
overloaded running of the connected device for a long time and the current
reaches 2-3 times of the rated current, it will trip. Also, the selection of the wrong
type of MCB causes tripping, like a motor, and requires a high starting current
so you have to select Type-C MCB for it if you have selected Type-B MCB then it
will take a high starting current, there are frequent trips during.
MCB Trip due to short Circuit
Friends, to explain this, I have made an incorrect connection in the diagram
below. A bulb is connected to an MCB on one side, and the neutral is connected
through a plug on the other side. You can see that the bulb's neutral and phase
are touching at one point. As soon as you turn on the MCB, it will trip.

Friends, to make the correct connection, the output wire from the MCB should
be connected to the top terminal of the bulb. This way, the connection will be
correct, and the MCB will not trip.

MCB Brands (Manufacturers) in India and the World

There are many local and global manufacturers available in the Indian market
with variations in design and cost, however the following products of MCB are
good and best in customer support Havells, Siemens, L&T, ABB, Schneider,
Polycab, Legrand, Sigma, Hager, CNC etc.

Friends, keep in mind, I am not promoting any brand here. I am just giving you
a suggestion. If you want, you can buy some of these good brands for your
home.
MCB Breaker
Friends, you have understood yourself well in detail about MCB. The rating of
MCB comes from 0.5 Amp to 100 Amp.

use of MCB
It protects us and the equipment by automatically tripping in case of overload
or short circuit faults. For this reason, it is also called Circuit Breaker.
I am sharing some photos with you. By looking at these you can find out what
this breaker looks like.
14. MCCB, ELCB/RCCB, RCBO, AFDD/AFCI

MCCB Breaker
You understand that this is the elder brother of MCB, MCCB. Its full form is a
Moulded Case Circuit Breaker. It has been made by updating MCB, meaning it
works in the same way as MCB. It protects the circuit from overload and short
circuits. In this, a port is provided to adjust the current. And its rating is more
than 63 Amp.
Another specialty of MCCB is that we get the option to install two coils inside it,
with the help of which coil (Shunt Trip) we can trip the MCCB remotely. With the
help of a second coil (Combination Switch), we can turn on our indicator in
feedback or can also send feedback to PLC or Relay. MCCB is also used for
automation.
I am showing you some images below related to MCCB (Molded Case Circuit
Breaker) and its automation.
MCCB Use For Automation and Heavy Load

How we use MCCB (Melded Case Circuit Breaker) in our panel is

explained below with some diagrams. By looking at these diagrams,
you can easily understand how MCCB is used.
ELCB/RCCB Breaker
ELCB (Earth-leakage circuit breaker) And RCCB (Residual current circuit breaker)
Both of these are the names of the same device. It is a current sensing device. It
is an important safety measure that protects the electrical circuits. It is capable
of sensing electrical leakage currents and protecting low-voltage circuits. The
operating principle of RCCB is like ELCB (Earth Leakage Circuit Breaker),
although ELCB is the oldest version.

The main function of ELCB/RCCB is to sense current leakage and protect against
electric shock. You can say that the main reason for using it is human safety.
It is widely used for protection against leakage currents of 30mA, 100mA, and
300mA. This is a highly effective form of shock protection.
RCCB It ensures 100% detection of leakage current and is available to sense AC
as well as DC leakage current.

RCCB has no connection with earth wire and hence it can trip when both the
currents (phase and neutral) are different and it withstands till both the currents
are equal.

ELCB is no better as it can only detect current flowing back through the
main earth wire.
I am sharing with you some photos of RCCB. By looking at these you can find out
what this breaker looks like.
Friends, I have shown you a chart below which is the chart of ampere. There
are 1000 milliamperes in 1 ampere. I have tried to show you how much
current our body can withstand. I would request all of you to use RCCB
whenever you make a connection anywhere
RCBO Breaker
Its full form is a Residual Current Circuit Breaker with Overcurrent protection.
Friends, this is a type of advanced circuit breaker. In this, we also get short circuit
protection and overload protection. It can do the work of both MCB and RCCB
simultaneously. If we install the RCCB breaker then we do not need to install MCB
and RCCB.
I am sharing some photos with you. By looking at these you can find out what
this breaker looks like.
AFDD/AFCI Breaker:
Arc fault detection device (AFDD), also called arc fault circuit interrupter (AFCI),
is a type of circuit breaker to protect against arc fault. Many times, when we drill
with a drill machine, many wires get cut a little and the wire becomes thin at that
point or a wire gets cut a little due to being pressed by some metal, then the
current passes but we do not realize it. That our wire has been cut somewhere.
Where the wire remains very thin, there is generated heat and after some time
due to heating, it starts burning and this fire later becomes very big and houses
and shops or showrooms also get burnt. To avoid such problems, the (AFDD)
breaker trips the circuit immediately.
I am sharing some photos with you. By looking at these you can find out what
this breaker looks like
15. 3 Phase electric meter connection with single Phase meter:
16. VMR relay connection (Voltage monitoring relay)

Friends, through the connection shown below, I have tried to explain how we can
connect a voltage monitoring relay in our home. By looking at this diagram, you can
easily install this device in your home.
17. What is the series board for electricians & how to use

Friends, a series board is a special type of board. Through this board, any
electrical device can be checked. With the help of this board, you can perform a
makeshift job like a Multimeter. If you don't have a Multimeter, you can use the
series board to check if any electrical equipment is working correctly or faulty.

It is effortless to make this board. I have provided two diagrams below. You can
easily create a series board by looking at these diagrams
18. Surge Protection Device (SPD):

Surge Protection Device (SPD) is an important tool that protects electrical

equipment in installations from voltage spikes or surges. These surges typically
occur due to lightning strikes, power failures, or issues in the power supply.
Voltage spikes can damage sensitive electronic devices, equipment, and wiring
systems.
Connection in Board:
1. Connect the Live Terminal: Connect the live terminal of the SPD to the
incoming live conductor from the main power supply. This conductor is
usually labelled as "L1" or "L."
2. Connect the Neutral Terminal: Connect the neutral terminal of the SPD
to the incoming neutral conductor. Ensure that the connection is secure
and properly insulated.
3. Connect the Earth Terminal: Connect the earth terminal of the SPD to the
earthing bar in the distribution panel. This is essential to properly ground
the SPD and protect against potential electrical hazards.
19. House wiring:

Friends, house wiring is a very easy task. I hope that if you have come to this page then
you must have read all the above pages thoroughly, how to select MCB for house
wiring. You must have learned properly how to select wires, yet here I show you a chart
that you can use for wire selection in-house wiring.

Friends, here I am showing you a basic chart that I have made with a lot of hard
work. By looking at this chart you can do wiring in any house and do the wiring.
Friends, I hope you can choose the right wire size for house wiring based on the
chart above. Now, I'll show you how to create a distribution board, which is the
main panel and a crucial part of house wiring.
To make the main panel, you need to know the total electrical load of your house.
If you're not sure about the load, don't worry. I have a list of all the electrical
equipment used in a house. You can check this list to see how many watts each
device uses and figure out the total load of your house.
Friends, I hope that now neither will you face any problem in selecting the size
of the wire nor will you face any problem in finding out the connecting load of
the house.
For wiring, we'll take wires from the main board and install an MCB (Miniature
Circuit Breaker) box either outside or inside the room on one side of the wall.
This box will have a double-pole main MCB and an RCCB (Residual Current Circuit
Breaker) based on the room's load rating. From this point, we can control the
entire room's lights, and we'll install separate single-pole MCBs for all power
sockets.
Friends, to set up a main board, you'll need a changeover switch, an ammeter, a
voltmeter, and an indicator. We will include the changeover switch inside the
main board. This way, if you need to use a generator in the future for events like
weddings or other functions, you can connect the generator’s output to the
changeover switch. This will also allow you to turn off the lights in the house
when needed using the changeover switch.
Friends, there are two types of changeover switches: mechanical and electrical.
You can use either one. I am showing you photos of both types. The electrical
changeover switch automatically switches to the alternate supply as soon as the
main power is cut.
Here, you should notice that I have taken the supply for a bulb and voltmeter
from above the terminal without making any cuts in the wire. Please make your
connections in the same way, without cutting the wire anywhere. I request you
to follow this practice.
Friends, here also you must have noticed that I have taken the wire from the
MCB from the main distribution board of one room to the main distribution
board of the other room. Similarly, friends, you too should not put any joint
inside the wiring. Do not think that it is too much. It will be installed properly if
you take the wiring from the MCB to the MCB box of the other room. You do not
have to cut the wire anywhere in between. If you cut, then the joint where the
cut is made starts getting heated slowly and after a time. After that, the wiring
gets damaged and gets burnt.
Friends, I am also sharing a video about house wiring. By clicking on this video,
you can watch it on YouTube. The video is in Hindi, but English subtitles are
provided to help you understand it better. After watching this, I don’t think you
will face any problems with house wiring.
20. House wiring with Inverter connection:

Step-by-step guide to connecting an inverter

Turn Off Power: Make sure the power source is turned off before you start.

1. Select Location: Choose a suitable location for the inverter installation, try
to place the inverter in a dry, well-ventilated area. It should be mounted
securely. preferably near the battery bank to minimize cable length and
voltage drop.

2. Turn Off Power: Ensure that the main power supply to the electrical panel
is switched off to prevent any electrical hazards during the installation.
3. Mount Inverter: Install the inverter securely on a flat, stable surface using
mounting brackets or screws provided with the inverter. Make sure there
is ample ventilation around the inverter to prevent overheating

Connect the Battery:

• Positive Terminal: Connect the positive (+) cable from the inverter to the
positive terminal of the battery.

• Negative Terminal: Connect the negative (-) cable from the inverter to the
negative terminal of the battery.
• Tighten Connections: Make sure the connections are tight and secure.

4. Connect AC Output: If the inverter has built-in AC outlets, you can directly
plug-in devices to these outlets. For larger inverters or grid-tied inverters,
connect the AC output terminals of the inverter to the electrical panel using
suitable gauge AC wiring and a circuit breaker.

5. Check Connections: Double-check all connections to ensure they are

secure and properly tightened to prevent any loose connections that could
lead to electrical issues.

6. Turn On Power: After completing the connections, turn on the main power
supply to the electrical panel and then turn on the inverter. Follow the
manufacturer's instructions for initializing and configuring the inverter
settings, if required.

7. Test Operation: Test the operation of the inverter by powering up

connected devices or appliances to verify that the inverter is functioning
correctly and providing the expected AC power output.
8. Safety Precautions: Always follow safety guidelines and local electrical
codes when installing and operating inverters to ensure safe and reliable
operation
Click on this video to watch it on YouTube
21. How to fit inverter with existing House/Room wiring.

Here’s how you can fit an inverter into an existing home wiring system so that
only essential points (like lights and fans) run on the inverter during a power
cut. Let me explain step by step:
1. Place the Inverter:
Place the inverter in a safe and well-ventilated area where maintenance
and cleaning can be done easily.

2. Connect the Battery to the Inverter:

First, connect the inverter battery to the inverter. Match the positive
terminal to positive and the negative terminal to negative. Ensure the
terminals are tightly secured to avoid sparking or loose connections.
3. Provide Incoming Power Supply to the Inverter:
Use a power board to supply incoming power to the inverter, ensuring it
gets both the phase (live) and neutral connections.
4. Follow Standard Wiring Rules:
When wiring the incoming power, make sure to keep the phase (live) wire
on the right-hand side and the neutral on the left-hand side of the
sockets. This standard rule applies to all sockets during wiring.

5. Connect the Output to the House Wiring:

Take a 3-pin plug and connect only the phase (live) wire on the right-hand
pin. Plug this into the 5-pin socket on the back of the inverter to connect it
to the house wiring.
For a visual guide, you can click on the video link provided to watch the process
on YouTube.
22. How to select Battery and Inverter for home:
Click on this video to watch it on YouTube.
23. Geyser connection:

Electrical appliances Geysers (water heaters) have several safety features:

1. Thermostat: This keeps the water at the right temperature. It turns off the
heating element when the water is hot enough, so it doesn’t overheat and
wastes less energy.
2. Auto Cut-Off: This safety feature turns off the heater if the water gets too
hot or if there’s a problem. This prevents accidents like the water boiling
over or the geyser catching fire.
3. Indicator Lights: These lights show what’s happening with the geyser.
They let you know if the geyser is on if it’s heating the water, or if there’s
an issue that needs fixing.

In short, thermostats control temperature, auto cut-off features prevent

overheating, indicator lights show the geyser’s status, and all these features help
keep the appliance safe and easy to use

Click on this video to watch it on YouTube.

24. Geyser fault and rectification:

Common Problems in Geysers and How to Fix Them at Home:

1. Water Not Heating:

➢ The heating element might be faulty.
➢ The thermostat may not be functioning properly, causing incorrect
temperature settings.

2. Water Overheating:
➢ A faulty thermostat may prevent the heater from turning off, leading to
overheating.
➢ The auto cut-off feature might not be working, causing the geyser to
overheat.
3. Water Leakage from the Geyser:
➢ Rust inside the geyser or loose pipe fittings can cause water leakage.
➢ Excessive pressure inside the geyser might also force water out.

4. Geyser Not Turning On:

➢ There could be an issue with the power supply.
➢ The fuse or internal wiring of the geyser might be damaged.
5. Strange Noises from the Geyser:
➢ Dirt or mineral deposits in the water may form a layer on the heating
element, causing unusual sounds.
Preventive Measures and Solutions:

• Regularly inspect and service the geyser to prevent these issues.

• Clean the heating element to remove mineral deposits.
• If there’s a significant problem, consult a professional electrician for
proper diagnosis and repair.
By clicking on this video, you can go to YouTube and watch this video.
25. Ceiling fan Connection: सील िंग फैन कनेक्शन

A ceiling fan has 3 or 4 wires coming from its coil, and you need to connect the
capacitor and power supply to these wires. From the image, you can see that the
fan has two types of coils: the inner one is called the Starting Coil, and the outer
one is the Running Coil. Sometimes, only three wires come from the fan. If the
wires from both the starting and running coils are joined at one point, this point
becomes neutral.

Sometimes, only three wires come out of the fan. If the wires from the starting
and running coils are joined together, that point becomes neutral. Take one wire
from the starting coil and one from the running coil. The two capacitor wires are
connected to both coils. One is taped to the capacitor wire, and the other wire
from the running coil is connected to the power supply (phase).
 Step 1: Identify the Winding

Step 2: Connect one end of both winding together

Step 3: Connect the Capacitor

Step 4: Connect the Power Supply

The diagram shows how to connect the wires to a ceiling fan. I’m also providing
a picture of the circuit diagram. By looking at this picture, you can see how to
make the connections for the ceiling fan
26. The ceiling fan wiring with the regulator
27. Staircase wiring with 2-Way Switch:

Friends, staircase wiring is very easy. There are 2 two-way switches installed in
this wiring, the first switch is installed at the bottom and the second switch is
installed at the top. The two ends of both switches are connected. We give input
at the middle point of the first switch take the output from the middle point of
the second switch and connect it to our lamp.
Friends, I have shown you the connection in the proper way below, you can make
the connection in this way, although this is an old method, in today's time there
are also switches connected to Wi-Fi that can be turned on and off from
anywhere.
28. The doorbell switch wiring
Friends, doorbells can also be connected like a bulb but today I am teaching you
the connection in a unique way. Suppose you do not want anyone to disturb you,
then you can connect the doorbell in such a way as I have shown below
29. Fridge connection single door & Double door:

The refrigerator uses several important components to keep everything

cool:

⚫ Thermostat: The thermostat is connected to the main power supply and

controls the temperature inside the refrigerator. When the temperature rises
above the set threshold, the thermostat signals the compressor to start
cooling.

⚫ Compressor: The compressor is the main power-consuming component in

the refrigerator. It is connected to the thermostat and receives signals to start
or stop based on temperature requirements. The compressor is powered
through the relay.

⚫ Relay: The relay is an electrical switch connected between the thermostat

and the compressor. It controls the power supply to the compressor, turning
it on or off as directed by the thermostat.

⚫ Door Switch: The door switch is connected in series with the interior light
and sometimes with the compressor circuit. When the refrigerator door is
opened, the door switch breaks the circuit, turning off the interior light and,
in some models, temporarily disabling the compressor to save energy and
prevent cold air loss.

⚫ OLP (Overload Protector): The overload protector is connected in series

with the compressor circuit. It monitors the current flowing through the
compressor. If the current exceeds a safe limit, indicating an overload or fault,
the OLP disconnects the power to the compressor, protecting it from
damage.

Overall, these components work together in the electrical connection of a

refrigerator to ensure efficient cooling, temperature control, energy savings,
and safety.
You can watch the videos on YouTube by clicking here. It explains the wiring for
a single-door refrigerator.
30. Washing machine connection:

The explanation of the electrical connections in a washing machine:

⚫ Motor: The motor is responsible for driving the washing machine's agitator or
drum. It is connected to the power supply and controlled by the wash timer and
other control mechanisms.

⚫ Wash Timer: The wash timer is a control device that determines the duration and
sequence of washing machine cycles, such as wash, rinse, and spin. It is
connected to the motor, spin motor, and other components to regulate their
operation.

⚫ Spin Motor: In addition to the main motor, some washing machines have a
separate spin motor dedicated to spinning the drum at high speeds during the spin
cycle.

⚫ Spin Timer: The spin timer is specifically responsible for controlling the spin cycle
duration and speed. It activates the spin motor to achieve the desired spin speed
for clothes drying.

⚫ Capacitor: A capacitor is often used in washing machines to provide an extra

boost of power to start the motor and spin the motor, especially for heavy loads. It
helps in the smooth starting and running of these motors.

⚫ Door Switch: The door switch is a safety feature that ensures the washing
machine operates only when the door is securely closed. It is connected to the
control circuit and interrupts power if the door is opened during operation.
You can click here to watch the video on YouTube.
31. Submersible automatic Starter Single-phase

Friends, we use a starter for our submersible pump at home. You might have
noticed that when our water tank becomes empty, we manually turn on the
starter, and when the tank is full, we manually turn it off. If you want this to
happen automatically.
where the motor starts when the tank is empty and stops when it is full.

you can set up automation for this. Click on the video below to see a proper
practical video on how to do this. I have been using this starter at home for the
past 3 years without any issues, so you might want to try making a starter like
this yourself.
You can click here to watch the video on YouTube.
32. What is the Ammeter & Voltmeter, how to use it:

An ammeter is an instrument used to measure current in a circuit. It is also called

an ampere meter. Electric currents are measured in amperes (A); hence it is
given this name. The ammeter is connected in series with the circuit in which the
current is to be measured.

There are two types of ammeters, Analog ammeters, and digital ammeters.
A voltmeter is a measuring instrument. It is used to measure the potential
difference between two points in an electrical or electronic circuit. It is called a
voltmeter in English. The voltmeter is connected in parallel to the circuit that we
want to measure.

A voltmeter has two terminals. These terminals are connected to the two points
where the potential difference is to be measured. The resistance between the
two ends of the voltmeter should be very high (ideally infinite).

There are two types of voltmeters, Analog meter, and digital meter.
33. What are NO and NC Button & how to use it:

• Full name of NO- (Normally Open)

This means, that these two points will remain far from each other in normal
conditions, if we provide an electrical supply at one point of NO, we will not
get it at the other point.

Suppose we start the electrical Contactor by giving supply to A1 and A2 points

of the electrical Contactor. Then this is not a normal condition. Meaning, that
after the electrical contractor starts, the condition will not be normal and at
that time the supply from one contact of our NO will be available with the
other contact.
• Full name of NC- (Normally Close)
This means that if our electrical Contactor is in normal condition, both our
contacts will be connected.

For example, if we provide electric supply at one point in NC, we will continue
to get it at other points. But when we start the electrical Contactor, our NC
contacts which are connected will move apart.
34. What is Contactor & how to use:

A contactor is an electrical switch that turns on or off when you provide power.
Unlike the switches in your home that you need to operate manually, a contactor
can be controlled remotely.

All contactors have A1 and A2 terminals used to start the contactor. Each
contactor has a label showing its coil voltage. For example, if it says (A1 A2-
240AC).
You need to supply 240/440 volts to the A1 and A2 points to make the
contactor work. (Need to check once the coil Voltage)
I’m sharing some photos with you so you can see what a contactor looks like.
35. What is a Capacitor Contactor & how to use

A capacitor duty contactor is a special type of contactor designed for switching

capacitors. I’m sharing some images below so you can see what it looks like.

Capacitor switching involves a high inrush current, so these contactors are used
with damping resistors. These resistors limit the amount of inrush current to a
safe level. Capacitor duty contactors are the best choice for switching capacitors
because they limit the inrush current and extend the life of the capacitors. They
are used in APFC panels for switching power capacitors.
36. What is an Auxiliary Contactor & how to use

Friends, an Auxiliary Contactor is also known as a helper contactor. It’s a type of

switch that can control other switches. An auxiliary contactor is mounted
mechanically on top & side of a contactor. It has additional NO (Normally Open)
and NC (Normally Closed) points. These points are used as needed, for
automation, to add indicators to a starter, or to control other devices.

I’m sharing some images below so you can see what it looks like.
37. What is a selector switch and how to use

Friends, a selector switch is an electrical control device. By turning its knob or

lever to different positions, you can choose between several options. It is
commonly used in industrial machinery panels, and motor starters, to switch
supply between two motors with one starter, and for automation.
38. What is a Float switch & how to use

Friends, a float switch is a type of sensor used to detect the level of a liquid inside
a tank. Inside the float sensor, there is a limit switch. When the float moves up
and down due to changes in the liquid level, the limit switch gets activated.

It is mostly used to detect the water level in a tank. When the tank fills up, it can
automatically turn off the motor or be used for an alarm.
39. Float switch connection
40. What is OLR (Overload relay)

You may have noticed that almost all motor starters have an overload
relay (OLR) installed. The full name of OLR is Overload Relay, and it is also
called a thermal overload relay.

An overload relay is an electrical device used to protect motors. It works by

sensing the current going into the motor. If the motor draws more current
than the relay is set to handle, the relay trips and cuts off the circuit, protecting
the motor. Inside the overload relay, there are bimetallic elements. The current
flowing through the motor passes through these bimetallic elements. If the
motor draws too much current, these elements heat up and bend. This bends
the relay breaks the circuit and turns off the motor.
41. MPCB (Motor Protection Circuit Breaker)
MPCB, or Motor Protection Circuit Breaker, is a special type of circuit
breaker designed to protect electric motors from electrical faults such as
overloads, short circuits, and phase failures. It is specifically designed to
meet the unique needs of motor circuits and includes both thermal and
magnetic protection features.

Friends, MPCB is well-known for its unique features. Overload Protection, Short-
Circuit Protection, Phase Failure Protection & Current Adjustable Settings.
42. What is Interlocking:
When a house, factory, showroom, or office uses two power supplies, such as
one from the grid and another from a generator, UPS, or solar, we use
interlocking.

The interlocking system ensures that only one contactor is on at a time, while
the other is off. Even if we try to turn on both manually, the interlocking will only
allow one contactor to be active at a time. We use NO (Normally Open) and NC
(Normally Closed) contacts for interlocking.

For example, interlocking is used in star-delta starters and for switching

between a diesel generator and a grid supply.

I’m sharing a video with you. Click on it to watch it on YouTube.

43. What is an Analog and digital timer & how to use

A timer is a device that can turn a machine on or off after a certain period.

For example, in a star-delta starter, the motor runs in star mode first and then
switches to delta mode after a few seconds. The timer’s job is to turn off the star
contactor and turn on the delta contactor.

Timers are used for automation. There are various types of timers based on their
work, but the most common ones are analog timers and digital timers. Digital
timers come in several types. I’ve made some videos about timers, and I’m
sharing the playlist link here.

Click on the video below to watch all my timer videos.

⚫ Functionality: These timers allow users to set specific time intervals for
turning electrical devices on or off automatically. They can be programmed
to operate multiple times a day or week, offering flexible scheduling options.

⚫ Digital Interface: They feature a digital display and controls for setting time,
days of the week, and programming modes. Some timers also include LCD
screens for easy viewing of settings.

⚫ Programmable Options: Users can program timers to activate or deactivate

connected devices at precise times, making them ideal for controlling
lighting, heating/cooling systems, water pumps, and more.

⚫ Memory Backup: Many digital timers have memory backup capabilities,

retaining programmed settings even during power outages.

⚫ Accuracy: Digital timers offer high accuracy in timekeeping, ensuring precise

control over scheduled operations.

⚫ Versatility: They come in various designs and configurations, including plug-

in timers for household use and panel-mounted timers for industrial
applications.

⚫ Benefits: Digital programmable timers help save energy by automating

device operation based on usage schedules. They also enhance convenience
by eliminating the need for manual switching and monitoring of devices.
44. What is a Starter:

A starter controls the on and off functions of a motor or any electrical

machine and protects it from overloading. It acts as both a controller and a
protection switch.

Motor starters are essential for ensuring the motor runs efficiently and
safely. They come in various types, such as direct-on-line (DOL) starters,
star-delta starters, and soft starters, each suited for different applications.

A motor starter is a device used to control the operation of an electric motor. It

performs several functions, including:

1. Starting and Stopping: It allows the motor to be turned on and off

safely.

2. Protection: It protects the motor from overloads, short circuits, and other
electrical faults.

3. Control: It may include features for controlling the speed and direction of
the motor.
45. Different Types of the Motor Starter:

Here are some different types of motor starters:

1. Direct-On-Line (DOL) Starter:

Description: Directly connects the motor to the power supply.

Usage: Suitable for small motors.

Advantages: Simple and cost-effective.

Disadvantages: High inrush current can cause a large voltage drop and
mechanical stress on the motor.

2. Star-Delta Starter:

Description: Initially starts the motor in a star configuration to reduce the

starting current and then switches to a delta configuration for normal operation.

Usage: Ideal for large motors.

Advantages: Reduces starting current and mechanical stress.

Disadvantages: More complex and requires additional components.

3. Soft Starter:

Description: Gradually increase the voltage supplied to the motor, allowing for a
smooth start.

Usage: Suitable for motors that require a gradual start.

Advantages: Reduces inrush current and mechanical stress, and extends motor
life.

Disadvantages: More expensive than DOL starters.

4. Variable Frequency Drive (VFD):

Description: Controls the motor speed by varying the frequency and voltage
supplied to the motor.

Usage: Ideal for applications requiring speed control and energy savings.

Advantages: Provides precise control of motor speed and can save energy.

Disadvantages: Expensive and complex.

5. Auto-Transformer Starter:

Description: Uses an autotransformer to reduce the voltage during the start-up

phase.

Usage: Suitable for large motors.

Advantages: Reduces starting current and mechanical stress.

Disadvantages: More complex and expensive.

Note: You can find this starter in older installations where it was commonly
used. It is no longer used in new installations.

6. Reversing Starter:

Description: Allows the motor to run in both directions by reversing the

connections of two of the motor's three phases.

Usage: Used in applications where the direction of the motor needs to be

changed.

Advantages: Provides flexibility in motor operation.

Disadvantages: Requires additional components for direction control.

Dear friends, each type of motor starter has its own specific use cases,
advantages, and disadvantages depending on the application and motor
requirements.
46. Star Connection Wiring:

Star Connection (Y-Connection):

When a motor winding is connected in a star (Y) configuration, the

following characteristics and effects can be observed:

⚫ Voltage: The voltage across each motor winding in a star connection is

reduced compared to the voltage across the winding in a delta (Δ)
connection. This reduction in voltage is by a factor of √3 (square root of 3),
which is approximately 1.732.

⚫ Current: The line current (current flowing through the supply lines) in a
star-connected motor is lower than the line current in a delta-connected
motor for the same power output. This reduction in current can lead to
reduced power losses and improved efficiency.

⚫ Phase Angle: In a star connection, the phase angle between the line current
and the phase voltage is 30 degrees, whereas in a delta connection, it is 0
degrees. This difference in phase angle affects the motor's performance
characteristics, such as torque and speed.
⚫ Starting Torque: Star-connected motors typically have lower starting
torque compared to delta-connected motors. However, they also have a
lower starting current, which can be advantageous in certain applications,
especially where starting under load is not critical.

⚫ Winding Configuration: In a star connection, the motor windings are

connected between phase terminals and a common neutral point. This
configuration allows for easy identification and connection of the winding,
simplifying motor wiring and maintenance.

Star Connection
Line Voltage=√3 Phase Voltage Line Current=Phase Current
47. Delta Connection Wirings:

Delta Connection (Δ-Connection):

• What it does: This setup is used to run the motor at full speed.
It allows the motor to use more power, which means it can
deliver higher performance.
• Summary: Delta connection is used for running the motor at full
speed.

When a motor winding is connected in a delta (Δ) configuration, several

effects and characteristics can be observed:

⚫ Voltage: The voltage across each motor winding in a delta connection is the
same as the supply voltage. This means that each winding experiences the
full voltage of the power supply, which can be advantageous for motors
requiring higher voltage levels.
⚫ Current: The line current (current flowing through the supply lines) in a
delta-connected motor is higher than in a star-connected motor for the
same power output. This higher current can result in increased power
losses but may also provide higher starting torque, making delta
connections suitable for applications requiring robust starting capabilities.
⚫ Phase Angle: In a delta connection, the phase angle between the line
current and the phase voltage is 0 degrees. This means that the current is in
phase with the voltage, leading to certain operational characteristics such as
high starting torque and consistent speed regulation.

⚫ Winding Configuration: In a delta connection, the motor windings are

connected in a closed-loop triangular configuration, with each winding
connected between two phase terminals. This configuration simplifies
motor wiring and allows for efficient power distribution.

⚫ Starting Torque: Delta-connected motors typically have higher starting

torque compared to star-connected motors. This can be advantageous in
applications where high torque is required during startup, such as in
pumps, compressors, or conveyor systems.

Delta Connection
Line Voltage=Phase Voltage Line Current=√3 Phase Current
48. How to Select OLR Relay for DOL Starter

Min Thermal Overload Relay Selection =70%xFull Load Current

Max Thermal Overload Relay Selection =120%xFull Load Current
Thermal overload Relay setting =100% x Full Load Current (Line)
Suppose one of our motors takes 10 amps of current or the full load
current of the motor is 10 amps, now we will select an overload relay of
7-12 amps for it.

When we connect the overload relay for the DOL starter, we will select an OLR
Relay of minimum 70% and a maximum of 120% rating of the full load current
of the motor.

You must have noticed that the overload relay installed in the DOL starter is
installed before the contactor after the MCB and in some starters it is also
installed below the contactor. Before our motor, the current is equal in both
conditions.

Which is the set point of our relay, we cannot keep it more than FLC, either
you can set it at full load current or check the current of the motor with a
multimeter to see what the running current is and add a factor of x 1.15 on
the running current, Like this we do the setting of the relay.

For example: let us assume that the running current of a motor is 15 Amps
running current and FLC is 20 Amps, then we will multiply our factor by x 1.15
On running current 15A (15×1.15 = 17.25) and now the setting of our relay will
come out to be 17.25Amp.
49. How to Select OLR Relay for Star Delta Starter

Min Thermal Overload Relay Selection = 70% x Full Load Current

Max Thermal Overload Relay Selection = 120% x Full Load Current
For the star delta starter, we select the overload relay in two ways, either by
installing the overload relay after MCB or by installing OLR below the Main
contactor. The setting of the relay will be different in both the positions, I show
you below.

Possibility No.1:

The set point for setting this relay will be set at the full load current of the motor,
just like we set the overload relay in a DOL starter.

Either you can check the running current of the motor on time with a multimeter
add a factor of x 1.15 to the running current and set your overload relay.
Possibility No.2:
If the overload is placed after the Point where the wiring Split into the
main and delta Contactor, the Size of the overload relay at 58% (1/1.732) of
the motor Full Load Current because we use 6 leads going to the motor,
and only 58% of the current goes through the main set of conductors
(connected to the main contractor)

In whichever star delta starter our relay is connected on the phase wire, to set
the relay, we divide the full load current of the motor by √3 or (1.732), and the
value that comes out is based on that value. We set up our relay.

For example: The full load current of a motor is 100A and our overload relay is
set in the phase wire, so now we will divide 100A by √3 / 1.732 and the value that
comes out will be 58A, so we have to set our overload relay at 58A have to set.
50. How to Select Contactor for DOL Motor Starter:

Size of Contactor = 100% X Full Load Current (Line)

When we select the contactor for Direct Online Starter (DOL), we must check the
full load current of the motor. Whatever is the full load current of our motor, we
install the contactor of the same rating for our motor.

Example: There is a 10kW motor

10kW = 415×√3×0.8

= 415×1.732×0.8
= 17.39Amp

We saw that the full load current of a 10kW motor would be 17.39 Amps. Now
whatever contactor we get that is bigger than this rating, we will install it on our
direct online starter.

Here below I am showing you a chart of a direct online starter, by looking

at this chart, you can also select the contactor MCB and wire/cable for the
starter.
51. How to Select Contactor for Star Delta Motor Starter:

Main and Delta Contactor

The Main and Delta contactors are smaller compared to the single contactors
used in a Direct Online starter because the Main and Delta contactors in the Star
Delta starter control winding currents only. The currents through the winding
are 1/√3 (58%) of the current in the line. These two contractors (Main Contactor
and Delta Contactor) are closed during the run. These rated at 58% of the current
rating of the motor.

(DOL) In a direct online starter, all the current flows in the motor through
only one contactor, similarly in our star delta starter, the same current
flows into the motor through two contactors, one is the main contactor and
the other is the delta contactor, so the value of current is That is √3 or 58℅
less than the line current.

Star Contactor
The third contactor is the star contactor, which only carries star current while the
motor is connected to the star in starting. The current in star winding is 1/√3=
(58%) of the current in delta, so this contactor can be rated at 1/3 (33%) of the
motor rating. The star contactor can be selected smaller than the others,
provided the star contactor pulls first before the main Contactor. Then no
current flows when the third contactor pulls.

The rating of the star contactor is 33% of the full load current of the motor.
Here below I am showing you a chart of a direct online starter, by looking
at this chart, you can also select the contactor MCB and wire/cable for the
starter.
52. How to Select the Right Circuit Breaker for Motor Starter:

When we select an MCB for our motor, we must see what the full load current of
the motor is. After that, we take an MCB of 250% rating of the full load current of
our motor. Mostly we use it in our starter. Use C Type MCB.
Because the tripping current of C Type MCB is 5-10 times.
Here below I’m showing you a chart, you can select your MCB by looking
at this chart.

Maximum Inverse Trip Circuit Breaker Size =250% x Full Load Line Current.

Types of Motor Circuit Breaker of FLC

Single Phase Motor 250%
3 Phase Motor 250%
Synchronous 250%
Direct Current 150%

For example: A 5HP motor is connected to a DOL starter. Now we will first
find its full load current.

Power = √3 × Voltage × Current ×Cos φ

5HP to kW = 5 × .75kW
3.75kW = 1.732×415×I×0.8
3750Watt = 575×I
I = 3750/575
I = 6.6 Amp

Now the starting current of our motor will be 6 to 7 times more, meaning the
starting current of a 5HP motor will be approximately 42-50 Amp.
Now what we will do is take out 150% of 6.6 Amp (6.6*150%/100) which will be
9.9 Amp. Now whatever MCB we have available in the market that is bigger than
this rating, we will install the same MCB on our motor.
53. How to Select the Right wire size for the motor starter:

Size of Cable for Single Motor

• The size of the Cable for the Branch circuit which has a motor connection is
125% of the Motor's Full Load Current Capacity.

• Example: what is the minimum rating in amperes for Cables supplying 1 No of

5 hp, 415-volt, 3-phase motor at 0.8 Power Factor. Full-load currents for 5 hp =
7Amp.

• Min Capacity of Cable= (7X125%) =8.75 Amp.

Size of Cable for Group of Motors or Electrical Load

Calculating the minimum Ampere Capacity of the Main feeder and Cable is
125% of the Highest Full Load Current + the Sum of the Full Load Current of the
remaining Motors.

Example: -

• Full-load currents for 5 hp = 7Amp.

• Full-load currents for 10 hp = 13Amp.
• Full-load currents for 15 hp = 19Amp.
• Full-load currents for 10 hp (1 Ph) = 21Amp.
• Here, the Capacity wise Large Motor is 15 HP but the Highest Full Load
current is 21Amp of 5hp Single Phase Motor so 125% of the Highest Full Load
current is 21X125%=26.25Amp

• Min Capacity of Cable= (26.25+7+13+19) =65.25 Amp

54. How to read electrical Drawing:
Friends, understanding electrical drawings is quite easy, but before you can
understand the drawing, you need to know about NO (Normal Open) and NC
(Normal Closed) push buttons.

• Full name of NO- (Normally Open)

This means, that these two points will remain far from each other in normal
conditions, if we provide an electrical supply at one point of NO, we will not
get it at the other point.

Suppose we start the electrical Contactor by giving supply to A1 and A2

points of the electrical Contractor. Then this is not a normal condition.
Meaning, that after the electrical contractor starts, the condition will not be
normal and at that time the supply from one contact of our NO will be
available with the other contact.
• Full name of NC- (Normally Close)
This means that if our electrical Contactor is in normal condition, both our
contacts will be connected.
Friends, I hope you have now understood the concept of NO & NC. Here, I am
providing three videos that have been created in a very simple way. By watching
these, you'll never forget the drawing concepts in your life and will learn to read
any drawing very effectively. Click on the drawing to directly watch the videos on
YouTube.
55. Single Phase Starter with One Capacitor & With One way
Switch Single Line diagram:

This starter is used to start and stop a motor of up to 1HP. It is commonly used
in places where the water level is 40 to 50 feet high, as the motor doesn't
experience much load in such cases. In these situations, we only use a capacitor
and operate the motor using a 16-amp switch to turn it on and off.
The single-line diagram of the starter has been shown to you. In this setup, the
supply flows from the MCB to the ammeter. After passing through the ammeter,
the supply goes into a one-way switch. From there, it is connected to the motor
terminals. The capacitor, known as the running capacitor, has its two wires
connected to the R and Y terminals of the motor.
Friends, you may have noticed here that I showed you RYB three terminals even
in a single-phase motor. The B terminal is considered neutral, and the capacitor
wires are connected to the R and Y terminals. However, there’s no need to get
confused; this is not a three-phase motor but a single-phase motor.
A single-phase motor has two windings: running winding and starting
winding. One end of each winding is joined together, and this common point is
called the B point, where we connect the neutral wire. The other end of the
running winding is named R, and the remaining end of the starting winding is
named Y. The capacitor wires are connected to these R and Y points.
The single-phase supply is connected to the R point, while the Y point remains
unused. I’m sharing some practical photos of single-phase starters and motors
so that you don’t get confused in the future about whether it’s a three-phase or
single-phase motor. Although three wires (RYB) come out of the motor, the
supply is connected only to the B (neutral) and R (phase) wires.
56. Single Phase Starter with One Capacitor & With One way
Switch-3D View:
Components: -
Quantity Device Name
1 Pc One Way Switch 16Amp
1 Pc Single Pole MCB
1 Pc Indicator Lamp On
1 Pc NO Push Button for Voltage test
1 Pc Running Capacitor
Wire As per motor Rating
1 Pc Ammeter
1 Pc Voltmeter

Below, I have shown the 3D view of the starter, which you can use as a
reference to make the connections. If you want to watch a video of this
starter, click on the icon of the starter to view the video.
57. Single Phase starter with Double Capacitor & With
Contactor – 3D View:
In this starter, the green push button has four terminals. When you press the
green push button, the supply flows from one terminal to the contactor and from
another terminal to the starting capacitor. In this starter, you need to hold the
green push button for about 3 to 5 seconds to ensure proper operation.

Components: -

Quantity Device Name

1 Pc 3Pole/ 2Pole Contactor & Over-Load Relay
1 Pc Single Pole MCB
1 Pc NC Push button for Motor Off
1 Pc 2 Pole NO push Button for Motor ON
1 Pc NO Push Button for Voltage test
1 Pc Running Capacitor
1 Pc Starting Capacitor
Wire As per motor Rating
1 Pc Ammeter
1 Pc Voltmeter
58. Single Phase MK1 starter (Double Capacitor)– 3D View:
This is an old-type starter used for both single-phase and three-phase
applications. It contains two capacitors: one is a running capacitor, and the
other is a starting capacitor. In this starter as well, you need to press and hold
the green push button for 3 to 5 seconds to ensure proper functioning.

If you want to watch a video of this starter, click on the icon of the starter to view
the video.
59. Single Phase Motor both Capacitor Connection & Control
wiring with Plug Top/MCB:

A single-phase motor has two capacitors because it cannot self-start. To

provide the starting torque, a starting capacitor is used in addition to the
running capacitor. For connecting the starting capacitor, a clutch plate,
also known as a centrifugal switch, is used. This switch disconnects the
starting capacitor once the motor reaches a certain speed, ensuring
efficient operation.

In some single-phase motors, you will find only one capacitor, such as in ceiling
fans, pedestal fans, or other small single-phase motors. This capacitor is called
a permanent capacitor. It not only provides starting torque but also remains
continuously in the circuit.

You may have noticed that if you remove the capacitor from a running fan, the
speed of the fan decreases significantly. This clearly shows that the capacitor
always remains active in the circuit, contributing to the motor's performance.

If you want to watch a video about this, click on the video icon to view it.
60. DOL Starter Working Principle
DOL (Direct On Line) Starter is a simple starter used to start and stop motors.
It is built using a contactor and is suitable for motors up to 5HP or smaller.
If a motor is started and kept running continuously for long durations, such as
10-12 hours, without frequent starts and stops, a DOL starter can even be used
for motors up to 10kW or larger. However, it is important to note that the DOL
starter does not reduce the starting current; it connects the motor directly to
the power supply.
To protect the motor, an overload relay is used. If there is any fault in the
motor, the overload relay automatically disconnects the power supply from the
contactor, ensuring safety.
The starter is equipped with red and green buttons to control the supply to
the contactor (red to stop and green to start). An auxiliary contactor is used
to hold the supply in the contactor, maintaining the motor's operation after it is
started.
Components: -
Quantity Device Name
1 Pc 3Pole Contactor & Over-Load Relay
1 Pc 3 Pole MCB/ MCCB
1 Pc Single Pole MCB 6Amp for Controlling
1 Pc NC Push button
1 Pc NO Push Button
3 Pc Indicator On, Off & Trip
Wire 1/1.5 Sq. mm
DOL Starter losses:-

• The starting current of a DOL Starter is very high, and it cannot be

reduced.

• When the starter is turned on, it causes the line voltage to drop
significantly, affecting all the devices connected to the same line.

Precautions to Take While Making Connections:

1. Power Supply Off:

o Always ensure the power supply is turned off before starting the
connections.
2. Proper Insulation:
o Use properly insulated wires to avoid short circuits or electric
shocks.
3. Tight Connections:
o Ensure all connections are tight to prevent loose contacts, which can
o Ensure that the NC (Normally Closed) and NO (Normally Open)
switches in the push button are tightly connected. This prevents any
issues when the push button is pressed.
o While making connections, use wires of the exact length needed.
Using extra wire can make the wiring look messy and affect the
neatness of the wiring layout.

After connecting the motor, run it to check if it is rotating in the correct

direction. If the motor is not rotating in the desired direction, swap any two
wires connected to the RYB terminals on the contactor. This will reverse the
motor's rotation and make it turn in the correct direction.
61. DOL Power Wiring Diagram & Power Wiring-3D View.

The DOL starter power circuit diagram is quite simple to create:

1. MCB (3-pole or 4-pole):

➢ Start with a 3-pole or 4-pole MCB to protect the circuit.

2. Contactor:

➢ Connect the output of the MCB to the contactor to control the motor's
power supply.

3. Overload Relay:

➢ Below the contactor, install an overload relay for motor protection. This
relay will cut off the supply in case of an overload or fault.

4. Motor Terminals:

➢ Connect the output of the overload relay to the motor terminals, which
can be configured in either star or delta connection as required by the
motor.
This setup ensures safe and efficient operation of the motor using a DOL
starter.
62. DOL Single line Control wiring 3 Phase 415 Volt
In this starter, the control wiring operates on 415 volts. The supply from the B
phase is taken and connected to a single-pole MCB.

• From the MCB, the supply goes to the overload relay.

• The supply then exits the overload relay and enters the NC (Normally
Closed) red push button.

• From the NC button, the supply flows to the NO (Normally Open) green
push button.

• From the NO button, the supply is sent to the contactor coil.

• On the other side, the supply from the Y phase is directly connected to the
other terminal of the contactor coil.
63. DOL Control wiring 3D View (3 Phase 415 Volt):
In some cases, you might have noticed that DOL starters do not use a neutral
connection. Instead, the contactor is controlled using two phases:

1. One phase is connected directly to the A2 point of the contactor (or

sometimes to the A1 point).

2. The other phase is controlled via push buttons (red and green).

➢ This phase passes through the push buttons, allowing the starter to be
turned on or off.

This setup allows the DOL starter to function effectively without needing a
neutral connection.
64. DOL Single line Control wiring (Single Phase 230 Volt):

In this starter, the control wiring operates on 230 volts, and the rest of the
wiring is similar to the previously mentioned starter.

• In the earlier starter, the contactor coil received two phases on both
sides.

• In this circuit, however, the contactor coil is supplied with:

1. One neutral on one side.

2. One phase on the other side.

This change ensures that the contactor operates on a 230V control supply
instead of a 415V phase-to-phase connection.
65. DOL Control wiring (Single Phase 230 Volt) – 3D View:
Components: -
Quantity Device Name
1 Pc 3Pole Contactor & Over-Load Relay
1 Pc 3 Pole MCB/ MCCB
1 Pc Single Pole MCB 6Amp for Controlling
1 Pc NC Push button
1 Pc NO Push Button
3 Pc Indicator On, Off & Trip
Wire 1/1.5 Sq. mm
66. DOL Starter Single line diagram with indicator:

To connect the indicators in the circuit:

1. ON Indicator Connection:
o Take a wire from the A1 point of the contactor and connect it to the

ON indicator.
o This will light up the ON indicator when the contactor is energized.

2. OFF Indicator Connection:

o Use the NC (Normally Closed) points of the contactor to connect

the OFF indicator.

o When the contactor turns ON, the NC points become NO, causing

the OFF indicator to turn off.

3. Trip Indicator Connection:
o For the Trip indicator, take a supply from the input point of the

Overload Relay (OLR) and connect it to the NO point of the relay.

o When the relay trips, the NO point closes, activating the Trip

indicator.
This setup ensures clear status indications for ON, OFF, and Trip conditions.
67. DOL Starter Control wiring with indicator - 3D View:
68. Automatic Water Level Controller

Friends, a Water Level Controller is also called a Liquid Level Controller. As I

explained earlier about the float switch, it is also a type of water level controller.

Some water level controllers are designed to display the level of water or liquid
in percentages like 25%, 50%, or 75%.

I am sharing a video with you that explains this topic in detail. Click on the video
to watch it properly. After watching, you will learn how to make the connections
for a liquid level controller, and any doubts you have related to it will be cleared.
Materials used in Direct On-Line Starter
Components: -
Quantity Device Name
1 Pc 3Pole Contactor & Over-Load Relay
1 Pc 3 Pole MCB/ MCCB
1 Pc Single Pole MCB 6Amp for Controlling
2 Pc NC Push button
2 Pc NO Push Button
3 Pc Indicator On, Off & Trip
Wire 1/1.5 Sq. mm

69. Single line diagram Remote wiring from 2 Places

In our kitchens, equipment like fresh air fans or exhaust fans are often controlled
from two locations:

1. From the kitchen itself.

2. From the area where the equipment is installed.

To achieve this, we configure a starter to be controlled from two locations.

Steps to Control a Starter from Two Locations:

1. Overload Relay Output:

o The output of the overload relay is connected in series with the NC

switches.

o The number of NC switches depends on the number of control points.

For example, if controlling from two locations, connect NC-1 and NC-
2 in series.

2. Connection of NC to NO:

o The output of the NC switches is connected to the input of the NO

push button.

3. NO to Contactor Coil:

o The output of the NO push button is connected to the contactor

coil.

This setup allows the equipment to be controlled from multiple locations

efficiently.
70. DOL Starter Remote wiring from 2 Places - 3D View
In the above circuit diagram, I have shown how we can control a starter from
two locations. This is the control diagram.

Now, I will show you how to make direct connections in the starter using this
control diagram. With these connections, you can implement the same
functionality in a real starter setup.
71. DOL Starter Singal line diagram Remote wiring from 3 Places

I have shown the control circuit diagram in this drawing, which explains how
to operate a starter from three different locations. This diagram illustrates the
setup and wiring required to control the starter for both ON and OFF operations
from three separate points.
72. DOL Starter Remote wiring from 3 Places - 3D View:
Components used in Starter
Components:-
Quantity Device Name
1 Pc 3Pole Contactor & Over-Load Relay
1 Pc 3 Pole MCB/ MCCB
1 Pc Float Switch
1 Pc Selector Switch for Auto & Manual
1 Pc Single Pole MCB 6Amp for Controlling
1 Pc NC Push button
1 Pc NO Push Button
3 Pc Indicator On, Off & Trip
Wire 1/1.5 Sq. mm
73. DOL Starter Singal line diagram with float switch and With
Selector Switch:

This starter is commonly used in industries for sump pumps, which are installed
in pits or underground areas filled with water. The float switch is utilized to
control the starter automatically.

Working of the Starter with Float Switch:

1. When water fills the pit, the float switch activates and sends a signal to the
starter's contactor.

➢ The NO (Normally Open) point of the float switch is used.

➢ As the float rises due to the water level, the NO point becomes NC
(Normally Closed), turning the starter ON.

2. The pump begins to operate, removing water from the pit.

3. Once the water is drained, the float switch moves back down.

• The NC point returns to NO, which stops the starter, and the pump turns
OFF automatically.

This setup ensures automatic control of the sump pump based on the water
level, eliminating the need for manual operation.

For filling rooftop water tanks, float switches are also used. These switches
automatically operate the motor when the water in the tank is depleted.

Additional Feature for Backup:

If the float switch malfunctions, a selector switch is used as a backup.

• The selector switch allows the motor to be operated in either Auto or

Manual mode:

o Auto Mode: The motor is controlled by the float switch.

o Manual Mode: The motor can be turned ON and OFF manually,

ensuring functionality even when the float switch is not working.
This setup provides flexibility and reliability for tank filling operations.
74. DOL Starter diagram with float switch and With Selector
Switch- 3D View:

A float switch typically has three wires. Here's how to identify and connect
them correctly:
Steps to Test and Connect the Float Switch:
1. Supply Phase to One Wire:
o Connect the phase supply to any one wire of the float switch.

o Keep the float switch in the downward position.

2. Check Output in the Remaining Two Wires:

o Using a tester or multimeter, check for an output in the other two

wires.
o If you get an output on one of the wires, note it.

3. Lift the Float Switch:

o Move the float switch to the upward position.

o Check if the output shifts to the other wire.

4. No Output on the Second Wire:

o If there's no output on the second wire, it means the phase supply is

connected to the wrong wire.

o Disconnect the phase from the current wire and connect it to

another wire.
o Repeat the testing by lifting and lowering the float switch.

5. Correct Connection:
o If the output alternates between the two wires as the float switch

moves up and down, the common wire (phase supply) is correctly

connected.
6. Multimeter Method (Optional):
o Use a multimeter to check continuity between the wires when the

float switch is up or down. This will also help identify the common
wire and the NO/NC connections.
By following these steps, you can ensure the float switch is properly
connected and functioning as intended.
75. DOL Starter Reverse Forward Single Line Power diagram:
Starter में प्रयोग होने वा ी सामग्री
Components: -
Quantity Device Name
2 Pc 3Pole Contactor
1 Pc Over-Load Relay
1 Pc 3 Pole MCB/ MCCB
1 Pc Single Pole MCB 6Amp for Controlling
1 Pc NC Push button
1 Pc NO Push Button
3 Pc Indicator On, Off & Trip
Wire 1/1.5 Sq. mm
76. DOL Starter Reverse Forward Power diagram -3D View:
77. DOL Starter Power wiring and control wiring with timer:
A Star Delta Starter is commonly used for motors rated 7.5 kW or above
(equivalent to 10 HP). However, there are some important considerations:
Key Points:
1. Standard Practice:
• For motors rated 7.5 kW/10 HP or higher, it is advisable to use a Star Delta
Starter to reduce starting current.
2. Misconception:
• Some believe that it is mandatory to use a Star Delta Starter for motors
above 5 HP. This is incorrect.
3. When to Use DOL Starter for Larger Motors:
• A DOL (Direct-On-Line) Starter can be used for motors up to 10 HP or
even larger motors (15 HP, 20 HP), provided the motor operates
infrequently (e.g., once or twice a week).
Conclusion:
The choice between DOL Starter and Star Delta Starter depends on:
• The motor size.
• Frequency of operation.
• The ability of the power supply system to handle high starting currents.
Why install star delta starter?
We use a Star Delta Starter to reduce the starting current (inrush current) of
a motor. This is essential because:
1. High Starting Current Risk:
o When a motor draws excessively high current during startup, it can
damage the motor winding.
o Excessive current can lead to overheating and potentially burn out
the motor windings, causing the motor to fail.
2. Solution with Star Delta Starter:
o The Star Delta Starter minimizes the inrush current by initially
starting the motor in the star connection.
o Once the motor gains speed, it switches to the delta connection for
normal operation.
This protects the motor and ensures a smooth startup without overloading the
electrical system.

What is starting current? (Inrush Current)

Friends, inrush current is also called starting current. It is simple to
understand.
For example:
• Suppose we have a motor.
• When we start the motor by supplying it with a 3-phase electrical supply,
the motor will draw a high amount of current at the beginning.
• The amount of current the motor takes at the moment of starting is called
the starting current or inrush current.
We use a Star-Delta Starter to reduce the starting current (inrush current) of
a motor.
• During startup, the motor operates in a star connection. This lowers the
voltage across the motor windings, reducing the inrush current.
• Once the motor reaches 70% to 80% of its rated RPM, it is switched from
star to delta connection. This ensures the motor receives full voltage for
optimal operation while protecting its windings from damage caused by
high starting current.
This process helps prevent the motor windings from overheating or getting
damaged during startup.

Now let’s understand how using a Star-Delta Starter reduces motor current.
When you look at the motor’s connection plate, you will see six points for
connections. During wiring, these points can be connected to the supply in two
different ways.
Star Connection

When we connect the motor in Star configuration, we short three points on

one side and connect the electrical supply to the remaining three points.

In Star connection, the motor windings are shorted together on one side. When
we supply power to the other three points, each winding of the motor receives
230 volts, which is single-phase voltage. This way, in Star connection, each
motor winding gets single-phase power.

In Delta connection, on the motor’s connection plate with six points, opposite
points are shorted using links. Then, electrical supply is connected to all points.
In Delta connection, each motor winding receives power from two phases,
meaning every winding gets 415 volts during this time.
Starter Power Wiring Required Components: -

Quantity Device Name

1 Pc Single Pole MCB 6A
1 Pc Neutral Strip/ MCB
3 Pc Auxiliary Contactor
3 Pc Indicator On, Off, Trip
1 Pc NC Push button Normally Open
1 Pc NO Push button Normally Closed
1 Pc Timer Relay Star Delta Timer
Wire 1/1.5 [Link] For Controlling

78. Star Delta Starter Power Wiring Single Line Diagram

79. Star Delta Starter Power wiring 3D View:

80. Star Delta Starter Control single-line diagram:

81. Star Delta Starter Power & Control Wiring 3D View:

82. Star Delta Starter single line diagram with Indicator:

83. Star Delta Starter Power & Control Wiring With indicator 3D

Friends, you can click on this diagram to watch its video if you want.

84. Star Delta Starter without Timer single Line Diagram:

85. Star Delta Starter without Timer-3D View:

86. Star Delta Starter without Timer Single Line Diagram with
Indicator:
87. Star Delta Starter without Timer with Indicator- 3D View:
88. Star Delta Starter Control from 2 Places Singal Line Diagram
Components used in Starter
Components: -
Quantity Device Name
3 Pc 3Pole Contactor
1 Pc Over-Load Relay
1 Pc Single Pole MCB 6A
1 Pc 3Pole/ 4Pole MCB/MCCB
1 Pc Neutral Strip/ MCB
3 Pc Auxiliary Contactor
3 Pc Indicator On, Off, Trip
1 Pc NC Push button Normally Open
1 Pc NO Push button Normally Closed
1 Pc Timer Relay Star Delta Timer
Wire 1/1.5 [Link] For Controlling
89. Star Delta Starter Control from 2 Places -3D View:
90. Star Delta Reverse Forward Starter Power Wiring Single Line
Diagram:
Components used in Starter
Quantity Device Name
4 Pc 3Pole Contactor
2 Pc Over-Load Relay
1 Pc Single Pole MCB 6A
1 Pc 3Pole/ 4Pole MCB/MCCB
1 Pc Neutral Strip/ MCB
4 Pc Auxiliary Contactor
4 Pc Indicator On(2Pc), Off, Trip
2 Pc NC Push button Normally Open
2 Pc NO Push button Normally Closed
1 Pc Timer Relay Star Delta Timer
Wire 1/1.5 [Link] For Controlling
91. Star Delta Reverse Forward Starter Power Wiring - 3D View:
92. Star Delta Reverse Forward Control Wiring Single Line
Diagram:

93. Star Delta Reverse Forward Control Diagram -3D View:

Friends, if you want, you can also watch its video by clicking on this diagram.
94. Star Delta Reverse Forward Control Wiring with indicator
Single Line Diagram:

95. Star Delta Reverse Forward Control Wiring with indicator:

Single Line Diagram- 3D View.
96. Soft Starter working principle:

If we talk about the main components of a soft starter, it includes 3 SCRs

arranged in parallel inside the soft starter. The primary function of a soft
starter is to provide a smooth start to the drive (motor), which helps
eliminate mechanical jerks.

When it comes to soft starter control, its control mechanism is similar to

that of a VFD (Variable Frequency Drive). However, unlike a VFD, which
uses a rectifier, filter, and inverter unit for control, a soft starter has a
microprocessor controller to manage the entire process.

Another significant advantage of a soft starter is that it does not generate

harmonics, which makes it highly reliable. The absence of harmonics is a
key benefit, making the soft starter a preferred choice in many
applications.

Soft Starter Applications: -

1. Blowers/ Fans
2. Vacuum Pump
3. Compressor
4. Conveyors
5. Etc
97. Variable frequency drive (VFD) working principle:

VDF has 3 main components.

1. रेक्क्िफायर(Rectifier)
2. फफल्िर(Filter)
3. इनविट र(Inverter)

Rectifier- The basic function of a rectifier circuit is to convert AC voltage

into DC voltage.

Once the AC voltage is converted into DC voltage, the filter unit comes into
play. The role of the filter unit is to smooth and filter the DC voltage
generated by the rectifier.

Filter Unit- In the filter unit, the DC voltage from the rectifier circuit is
checked to ensure it does not contain any AC voltage components. The
filter unit processes the DC voltage, removing any remaining AC traits,
and produces pure DC voltage.

Inverter Unit- Once the DC voltage is filtered through the filter unit, the
inverter unit takes over and converts the DC voltage back into AC
voltage. The AC voltage obtained from the VFD is in a rectified form,
meaning it can be adjusted as needed. This allows us to modify the AC
voltage as required and easily control the motor's speed using the AC
voltage provided by the VFD.

VFD Applications: -

6. Blowers
7. Cooling Towers
8. Compressor
9. Pumping Stations
10. Modern Lift System
11. Boilers
12. Etc
98. VFD Remote wiring with push button:
99. VFD wiring with Limit Switch in conveyor