Three-phase motors typically have six lead wires coming from the stator windings, with two wires per phase. These are commonly referred to as the 'head' and 'tail' ends of each winding. The first phase winding’s head is labeled D1, and its tail is labeled D4. The second phase winding's head is marked D2, and its tail is D5. For the third phase, the head is D3, and the tail is D6. These six wires are connected to a terminal block inside the motor junction box, labeled accordingly as D1 through D6, as shown in Figure 1. The configuration of these windings can be either star or delta. In a star connection, the three tail ends (D4, D5, D6) are joined together using copper bars, while the heads (D1, D2, D3) are connected to the three-phase power supply lines (A, B, C). This method is often used for lower voltage applications, as it reduces the voltage across each winding. On the other hand, a delta connection involves connecting the head of one winding to the tail of another. Specifically, D1 is connected to D6, D2 to D4, and D3 to D5. These connections are made on the wiring board, and then each pair is linked to the corresponding power line. This setup allows the motor to operate at higher voltages but requires careful installation to avoid errors. It’s crucial to follow the manufacturer’s specifications when choosing between star or delta configurations. These details are usually indicated on the motor’s nameplate. The head ends of the windings are pre-set by the manufacturer and should not be reversed individually, as this could cause wiring errors. However, all head ends can be reversed together if needed, such as swapping D1, D2, D3 with D4, D5, D6, provided the entire system remains consistent. If the wiring is incorrect or the head/tail labels are misinterpreted, the motor may fail to start. Prolonged operation under such conditions can result in excessive starting current, overheating, and potential damage to the motor windings or even a short circuit in the power supply.
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