The three-phase stator winding of a motor consists of three separate windings, each with two lead wires. These are commonly referred to as the "head" and "tail" ends of the winding. Typically, the first phase winding's head is labeled D1, and its tail is D4. The second phase winding’s head is D2, and its tail is D5. The third phase winding’s head is D3, and its tail is D6. All six lead wires are connected to a terminal block inside the junction box, marked accordingly from D1 to D6, as shown in Figure 1. These six terminals can be connected in either a star (Y) or delta (Δ) configuration, depending on the motor's design and requirements. In a star connection, the tails (D4, D5, D6) are connected together using copper bars, while the heads (D1, D2, D3) are connected to the three-phase power supply lines A, B, and C respectively, as illustrated in Figure 2. In a delta connection, the head of one winding is connected to the tail of another. Specifically, D1 connects to D6, D2 to D4, and D3 to D5. These connections are made using copper bars on the wiring board, and then each pair is connected to the corresponding phase of the power supply, as shown in Figure 3. The correct wiring method—star or delta—must always follow the manufacturer's specifications, which are usually indicated on the motor's nameplate. It is important to note that the head ends of the windings are pre-set by the manufacturer and should not be reversed individually. However, all three head ends can be swapped together if needed, for example, by using the tails (D4, D5, D6) as the new heads and the heads (D1, D2, D3) as the new tails. This ensures proper operation without causing errors. If the wiring is incorrect or the head/tail labels are mixed up, the motor may fail to start. Prolonged operation under such conditions can cause excessive starting current, leading to overheating, reduced lifespan, and even damage to the windings or a short circuit in the power supply system.
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