Ramesh Meti, profile picture
Uploaded byRamesh Meti
2,841 views

Schneider electrical handbook

Electric fires can be caused by short circuits, overloading, poor insulation, or lightning. Fires are classified based on the type of fuel source - Class A for solids, Class B for liquids, Class C for gases, and Class D for metals. The right type of fire extinguisher must be used for each class of fire, such as dry chemical powder or CO2 extinguishers for electrical fires, in order to effectively put out the fire.

Embed presentation

1 / 128
2 / 128
3 / 128
4 / 128
5 / 128
6 / 128
7 / 128
8 / 128
9 / 128
10 / 128
11 / 128
12 / 128
13 / 128
14 / 128
15 / 128
16 / 128
17 / 128
18 / 128
19 / 128
20 / 128
21 / 128
22 / 128
23 / 128
24 / 128
25 / 128
26 / 128
27 / 128
28 / 128
29 / 128
30 / 128
31 / 128
32 / 128
33 / 128
34 / 128
35 / 128
36 / 128
37 / 128
38 / 128
39 / 128
40 / 128
41 / 128
42 / 128
43 / 128
44 / 128
45 / 128
46 / 128
47 / 128
48 / 128
49 / 128
50 / 128
51 / 128
52 / 128
53 / 128
54 / 128
55 / 128
56 / 128
57 / 128
58 / 128
59 / 128
60 / 128
61 / 128
62 / 128
Most read
63 / 128
64 / 128
Most read
65 / 128
66 / 128
67 / 128
68 / 128
69 / 128
70 / 128
71 / 128
72 / 128
73 / 128
74 / 128
75 / 128
76 / 128
77 / 128
78 / 128
79 / 128
80 / 128
81 / 128
82 / 128
83 / 128
84 / 128
85 / 128
86 / 128
87 / 128
88 / 128
89 / 128
90 / 128
91 / 128
92 / 128
93 / 128
94 / 128
95 / 128
96 / 128
97 / 128
98 / 128
99 / 128
100 / 128
101 / 128
102 / 128
103 / 128
104 / 128
105 / 128
106 / 128
107 / 128
108 / 128
Most read
109 / 128
110 / 128
111 / 128
112 / 128
113 / 128
114 / 128
115 / 128
116 / 128
117 / 128
118 / 128
119 / 128
120 / 128
121 / 128
122 / 128
123 / 128
124 / 128
125 / 128
126 / 128
127 / 128
128 / 128
Electrician Training Program, India Domain Handbook for Assam Nagaland Manipur Mizoram Tripura Arunachal Pradesh Nagaland Manipur Mizoram Tripura Arunachal Pradesh Sikkim Nepal Jammu and Kashmir Himachal Pradesh Punjab Haryana Rajasthan Gujrat Madhya Pradesh K e r a l a Goa Goa Andhra Pradesh Orissa West Bengal Jharkhand Uttar Pradesh Delhi Chattisgarh Meghalaya Bihar Tamil Nadu Karnataka Maharastra Andhra Pradesh Orissa West Bengal Jharkhand Uttar Pradesh Chattisgarh Meghalaya Bihar Tamil Nadu Karnataka Maharastra Chennai (2) Bangalore (2) Jumaikella Hyderabad (2) Chinchwad Delhi (2) Lucknow Bhubaneswar Ranchi Kolkata Shillong Patna Purnea Brahmapur Rajam Vijayawada Madurai Tirunelveli Kanyakumari Uttarakhand Electrical Training Knowledge Partner Schneider Electric Sponsored by: Schneider Electric India Foundation
PREFACE In modern education phraseology, the word “facilitator” is increasingly taking the place of “teacher”. As the word suggests, a facilitator is a person who facilitates, or who makes things easier. To a large extent, the success of the training program – or any other classroom-based program for that matter depends on the trainers’ ability to assume the role of a facilitator. The ideal facilitator… … connects with each of his students, and not just a few “good” ones … is a keen learner himself … understands his/her students, and not judge them …does not hesitate in giving candid feedback to the learners, but words his/her feedback very carefully … has enormous patience … knows his/her subject very well, but never flaunts what he knows … is willing to admit his/her shortcomings in front of the class … progressively makes himself/herself redundant in the classroom process Different Strokes for Different Folks A very important aspect of good facilitation is the facilitator’s ability to look at each learner as a unique, independent individual, with specific learning needs and capacity. The facilitator should make the effort of getting to know each of his/her learners at a personal level – to find out the background, the environment at home, likes and dislikes, what makes the person tick. He/she should objectively assess the initial (baseline) level of each learner, instead of having a “general” impression about the whole group. Armed with this information, the facilitator can use different approaches with different learners. A peep into the Classroom What to expect in a classroom for adults Perhaps the biggest mistake that some teachers tend to make in an adult classroom is to treat the learners not as adults but as children. This may happen when the teacher is older than the students in general, or when the teacher is used to taking classes for younger children. Learners above the age of 18-20 are sufficiently mature in their worldview and understanding to be treated as young adults – a condescending attitude towards them would hinder the learning process at the outset.
Specifically, the teacher of an adult classroom should remember that adult learners… can decide for themselves what is important to be learned. need to validate the information based on their beliefs and experience. expect what they are learning to be immediately useful. have much experience upon which to draw – may have fixed viewpoints. have a significant ability to serve as a knowledgeable resource to the teacher and fellow learners. Key challenges in a Classroom While the points listed above bring out some of the ways in which a classroom with adult learners can be different from one with children, there are also several things common to all classrooms. Here’s a shortlist of some of the key challenges teachers face in a classroom:  Lack of interest  Lack of confidence  Unwillingness to participate  Domination by one or two learners  Variation in levels across learners  Irregular attendance  Slow learners Most of these challenges can be effectively tackled by following the principles outlined in the earlier section on facilitation. Also, handling these situations comes with practice – as a teacher spends more time in the classroom with a varied group of learners, he would become more and more adept at handling challenging situations inside the classroom.
This handbook contains four sections: Section 1: Theory Pages 1-42 Section 2: Basic Electricals Pages 43-70 Section 3: Wiring Pages 71-100 Section 4: Repairs & Maintenance of Home Appliances Pages 101-121
CONTENT - Theory Chapter Name of the Topic Page No Day 1 Tools - uses and safety 1 2 2 Symbols – Switches and sockets 2 5 3 Safety Precautions – Getting shock, prevention, fuse, MCB, Fire, Earthing 4 6 4 Work, Power, Energy – Voltage, current, Resistance , Watts, KWH etc 10 8 5 Ohm’s Law – Series and Parallel circuits, comparisons 12 7 6 Conductors and Insulators – Introduction, types, materials, wires, gauges, cables 14 30 & 31 7 Electrical Accessories – Switches, sockets etc 18 9 8 Wiring system – Types, testing, earthing, distribution etc 21 16 9 Electricity – History Sources, effects and uses 27 4 10 AC/DC/ Polyphase - Basics, difference, connections, comparisons, advantages 30 38-40 11 Generators and Motors – Principles, parts, uses, functions, starters, general maintenance 32 55-56 12 Transformer – Principle, trypes, parts, cooling methods and maintenance 39 57-58 13 UPS – basics, connections and maintenance 41 59-60
CONTENT - Practical Exp No. Experiment Page no Day 1 Measurement of wire sizes 43 1 2 Skinning cable ends 45 3 3 Making of simple twist joints 47 3 4 Making of Tee joint in stranded conductors 49 3 5 Soldering of the joints 51 3 6 Termination of cable ends 53 3 7 Crimping of cable ends 54 3 8 Identify the phase and neutral in single phase AC supply 56 4 9 Identify, dismantle, sketch and assemble electrical accessories 58 4 10 Study of multi meter 61 4 11 Making of Test board 63 4 12 Assemble of single T/L fitting 65 10 13 Assemble of twin T/L fitting 67 11 14 One light control by one switch 69 12 15 One socket control by one switch 70 13 16 Complete wiring of a room 71 14 17 Two light control by two switches 73 15 18 Making of pipe earthling connection 74 16 19 Fixing of tube light fitting 77 17 20 Complete wiring of 1BHK House 79 18-19 21 Fixing of a ceiling fan controlled by switch 81 20-21 22 Fan control by regulator through switch 86 22 23 House Power socket controlled by DP switches 88 23 24 Complete wiring of 2BHK 89 24-26 25 Five lights controlled by five switches 90 27 26 Telephone and cable socket 91 28-29 27 Complete wiring of 3BHK House 92 30-31 28 Hotel and mini lodge wiring of six rooms 93 32-34 29 Wiring of corridor lighting 95 35-37 30 Knowledge of DOL starter 96 41-43 31 Manual star delta starter 99 44-46 32 Assemble and repair of non-automatic iron 101 47 33 Repair of automatic electric iron 103 48 34 Service and repair of a wet grinder 106 49 35 Service and repair of a Geyser 109 50 36 Fixing and repair of table fan 112 51-52 37 Assemble and repair of Food mixer 115 53 38 Assemble and repair of kettle 121 54
1 CHAPTER I: TOOLS Identification, uses and safety Introduction A good craftsman needs good tools to be able to do his work well. It is therefore important that we know about different tools used in electrical applications, as well as power tools for industrial purposes. Aim To gain an understanding of various electrical tools. Objectives At the end of this class, you should be able to:  Name the basic hand tools and their classification.  Give full specification of each tool.  Explain their uses.  Demonstrate their application. Types of Tools  Basic tools: Combination pliers, screw driver set, line tester, nose pliers, ball pane, cross pin, sledge hammers, electric knife, etc.  Measuring tools: Measuring tape, analog meters, digital meters, wire gauge, tri- square, etc.,  Cutting & chasing tools: Hand saw, tennon saw, knife, chisels, drilling tools, etc.  Power tools: Drilling machine, chasing machine, cutting machine, demolition machine, etc.  Testing tools: Test lamp, digital multimeter, clamp meter, line tester 500v, test lamp, etc. Tool specifications (To be explained tool- wise, along with purpose and precautions to be followed). Demonstration (The trainer should apply the „Why, What, When, Where, Who, Which and How‟ technique to activate the aspirants‟ minds). Review / Assessment  List out the tools used by an MSW technician.  Explain the uses of various tolls and precautions to be followed.  Describe test lamp, digital multimeter, clamp meter, line tester, etc.  Explain the uses of power tools. Reference Basic Electrical Engineering by Mittal & Mehta
2 CHAPTER II: SYMBOLS Introduction In any complicated circuit diagram of the electrical installation in a multi-storied building / complex / industrial workshop, the electrical circuits consists of fixtures, fittings, equipment and machinery as a main utility and are connected to various protective and operational devices with / without measuring devices for easy and efficient operation. In electrical engineering, it is a common practice to employ graphical symbols to denote the various means and devices used when making diagrams of connections. These symbols serve the purpose of expressing the component / equipment of fixtures for easy symbolic representation. Without knowing these symbols it is difficult to read the circuit diagram giving the plan of electrical installation or connection. The standard symbols are listed in Code 2032 (Parts 1 to 18). Therefore as an electrical technician you should be able to draw and identify symbols.
3
4 CHAPTER III: SAFETY PRECAUTION Getting shock, prevention, fuse, MCB, Fire, types, causes, earthing Introduction Electricity helps us in many ways. But it can take a lot more than it gives us, and can be dangerous if it is not treated properly. So we need to be very careful while working with the live supply. Aim To understand electrical safety, electrical shock and First Aid Objectives After completing this course, you should be able to:  Explain the safety precautions  Know precautions to be taken to prevent electric shock.  Explain causes of electric shocks, effects and shock treatment.  Demonstrate Cardio-Pulmonary Resuscitation (CPR) Safety Precautions  Careful handling of electrical appliances, using insulated hand tools, using correct rating fuses, effective earthing.  Metallic parts, using of hand gloves, using rubber mat, never tamper unnecessarily with live lines and never use damaged appliances. Causes of Electric Shock  Carelessness  Accidental  Over confidence  Lack of awareness / ignorance  Natural causes (lightning etc.) Effects of Shock on the Human Body On the brain, body, kidney, etc. (refer to text books) The Severity of a Shock Depends on:  Duration of current flow  Amount of current  Path of flow of current -location  Type of energy and line voltage, etc. An electric shock occurs by touching:  Phase and natural simultaneously  Phase conductor and standing on ground  A metallic part, when current is leaking. Treating Shock Cardio-Pulmonary Resuscitation (CPR) (Trainer to give live demonstration) Safety experts prefer the use of mouth-to-mouth resuscitation because it moves the largest volume of air into and out of the victim‟s lungs. The steps of application are described below:
5 1. The victim should be laid on his back with his head turned to one side and his mouth cleared of any saliva or foreign objects (e.g. dental plates) by insertion of the operator‟s thumb. Waste no time! 2. His head is then placed as far back as possible so that his neck is extended, chin toward ceiling. Mouth should drop open. 3. The operator uses one hand to support the victim‟s neck to keep head in proper position and then closes the victim‟s nose with his other hand (Figure 2). 4. After taking a deep breath, the operator places his mouth completely over the victim‟s mouth with airtight contact. The victim‟s mouth should not be held open too wide as it must be totally covered by the operator‟s lips. 5. The operator then breathes or blows into the victim‟s mouth, forcefully for adults and gently for children. The victim‟s chest should be watched, and as soon as it rises, the blowing should be stopped and the operator‟s mouth quickly removed from the mouth of the victim, allowing him to exhale passively. 6. The jaw must be held in an elevated position on both the inspiration and expiration phases, preferably by supporting the victim‟s neck. 7. If the chest does not rise, the position of the head and jaw should be improved and the blowing done more forcefully. If the victim‟s lungs are still not ventilated, his airway may be obstructed. Try the Heimlich Maneuver described on the wall card. 8. The cycle of inhalation and exhalation should be repeated 12 times per minute for adults. 9. If the victim‟s stomach swells during resuscitation, air may be entering it. This may be corrected by the operator gently pressing on the victim‟s stomach during exhalation. (Allow each aspirant to practice CPR) Review / assessment  Causes of electric shock  Effects of electric shock  CPR and its administration Reference First Aid (guest lecture by a doctor) Skill Cardio-Pulmonary Resuscitation (CPR)
6 CAUSES OF ELECTRIC FIRE, AND EQUIPMENT USED TO CEASE FIRE Introduction When a conductor carrying electric current gets overloaded, it heats up and softens the insulating cable. This may lead to a short circuit and fire. It is therefore important that we understand various types of fire and how to put them out with fire extinguishers. Aim To understand various causes / types of fire and how to extinguish them Objectives At the end of this lesson you should be able to:  Understand what is fire and its chemistry  Understand various causes of fires  Know their classification and mechanism involved  Use the right fire extinguisher Causes of electric fire Fire is a chain of chemical reaction, caused by combustion of inflammable material producing heat, light and smoke. The reasons for a fire could be:  Improper / substandard cables for wiring  Short circuits  Overloading the equipment  Maintenance negligence  Inadequate / poor insulation  Lightning Chemistry of fire The main components of fire are: Oxygen, Fuel and Heat (energy) Classification of fires S. No Type of fire Name of fire Source Fire extinguishers used 1 Class A Solid fires Wood, cloth paper A class fire extinguishers 2 Class B Liquid fire Petrol, fuel Dry Chemical Powder (DCP) 3 Class C Gas fire LPG gas Dry Chemical Powder (DCP) 4 Class – D Metal Fire Sodium, Magnesium ABC Fire extinguishers 5 Electrically Started Fires (ESF) Electrical Fire Electrically Starts ABC Fire extinguishers, CO2 Gas
7 Types of Fire Extinguishers Soda acid, Water-CO2, Form-type, Dry Chemical Powder (DCP), CO2 gas, ABC Powder Extinguisher Pressurizing mechanism in a Fire Extinguisher  Gas cartridge (CO2, water)  Spot pressure (soda, acid, and gas)  Stored pressure (readily available) Advantages of ABC Fire Extinguishers  Very easy to handle  Anybody can operate  Can be located at the level of pressure  Very economical and effective  Can be used for any type of fire (Class A / B / C)  Readily available with stored pressure Review / Assessment  Fire and its chemistry  Different types of fires.  Different types of fire extinguishers.  Advantages of ABC fire extinguisher.  What is stored pressure? EARTHING AND ITS METHODS (IS CODE 3043) Introduction Electricity today is playing an ever increasing role in the lives of every human being. Increased use of electricity has resulted in increased danger to human beings. When lightening occurs, it not only damages consumer‟s premises but it also destroys property and lives. So today Earthing is considered the most essential provision of any electric supply system. But unfortunately it is the most neglected aspect in house wiring and in many cases even in industrial and commercial wiring. So earthing is thus laid down as a statutory requirement in Indian electricity rules so as a trainer / trainee we need to understand
8 and implement it on grounds. Hence today we discuss about Earthing. Aim To facilitate learning of Earthing and its needs through demonstration and Practical session Teaching and Learning Methodology Lecture, Video, Demo and Practical Learning Objective After completion of this session an aspirant shall be able to  Define Earthing  Explain the purpose of Earthing  Differentiate methods of Earthing and emphasis on best methods  Factors affecting the resistance and related ISI Rules Preview What is Earthing? A wire coming from the ground 2.5m to 3m deep from an electrode (Plate) is called Earthing. A wire 2.5m to 3m long connected from an electrode (plate) to the main switch board to avoid shock is called Earthing. Note: The metal plate, copper plate, rod or conductor is called as earth electrode. Purpose / Objects of Earthing  To save human life from Danger / shock  To protect large buildings and towers from lightening  To protect all machines fed from OH lines from lightening arresters  To maintain the line voltage  To provide easy return path for leakage current  Good Earthing is that which gives low resistance and enables smooth flow of heavy current Methods of Earthing There are mainly two methods of Earthing. They are: a. Plate Earthing (most common and effective method) b. Pipe Earthing ISI Rules  The standard Earthing code is IS 3043  The Earth pit must be 1 ½ m distance from the building wall  The earth wire must be of the same material as that of the electrode used  The cross sectional area of the earth wire should not be less than 8 SWG  The size of the earth conductor should not be less than half the size of the line conductor  All the joints must be properly joint, bolted, soldered or brazed  All the metal parts, motors, generators and other appliances must be properly connected by the earth conductor  All the third pin of sockets must be connected to earth conductor  Every stay wire must be Earthed Latest Trends Mat Earthing
9 Conclusion It is very necessary to know about Earthing and to motivate and educate the consumer about the need for it. Summary / Assessment a. Define the Earthing and explain the purpose? b. Which type of Earthing is effective? Why? c. How do you reduce resistance of an earth electrode? d. List down the IS rules related to good Earthing. FAQ Why are charcoal and salt used for Earthing? Is copper Earthing is effective? Reference General Information, ICPCI Hand book Practical Earthing and testing of earth resistance.
10 CHAPTER IV: WORK, POWER AND ENERGY Voltage, current, Resistance, Watts, KWH etc Introduction It is commonly understood that „work‟ is accomplished when „energy‟ is expended for the purpose. It is therefore necessary to understand the link between work, power and energy. Aim To understand the concept of work, power and energy Teaching and Learning Methodology Lecture, charts, practical and classroom training Objectives At the end of this session the aspirant should be able to:  Define work, power and energy and their units.  Distinguish between work, power and energy.  Calculate the power and energy consumption. Work When force is applied on a body, and the body moves in the direction of the force, work is said to have been done. Work (W) = Force (F) x Distance (D) The unit of work is joule (MKS system) or erg (CGS system). The unit of force is Newton in MKS system. Power Power is the rate of doing work. Power (P) = Work done (W) / Time taken (T) The unit of power is joules / second or watts / second. I kilowatt (kW) = 1000 w Another unit of power is hp; 1 hp = 746 w, or 1.34 hp in MKS system; 1 kW = 1.36 hp Energy Energy is the capacity for doing work. Energy exists in several forms, which may be interchanged. 1 joule = 1 Newton / meter A small unit of power is watt / second A bigger unit of power is kwh (also called (botu); 1 botu = 1000 w or 1 kwh = 36,00,000 joules Energy Calculation Calculate the total load consumption for an electric installation consisting of the following: S. No. Name of point No. of points Load 1 Lamps 10 100 2 Ceiling fans 8 75 3 Electric heater 1 1500 4 Motor 1.5 hp 1 - Total load Calculate the total units consumed in a month, when the cost of energy is First 200 units @ Rs.1.50 / unit; Second 200 units @ Rs.2.00 / unit; Rest @ Rs.2.50 / unit
11 Solution S. No. Name of point No. of points Load Total hours Total 1 Lamps 10 100 8 8000 wh 2 Ceiling fans 8 75 10 6000 wh 3 Electric heater 1 1500 3 4500 wh 4 Motor 1.5 hp 1 (735.5 w) - 4 4413 wh Total load 22913wh / per day Energy consumed in the month = 30 x 22913 wh = 687390 wh / 1000 = 687.39 kwh Billing Calculation First 200 units = Rs.1.50 x 200 = Rs.300; Next 200 units = Rs.2.00 x 200 = Rs.400; Rest of the units = Rs. 2.50 x 287.39 = Rs.718.47. Total billing for the month = Rs.300 + Rs.400 + Rs.718.47 = Rs.1418.47 Review / Assessment  Define work, power and energy. What are their respective units?  Calculate the power and consumption of your house as per the existing rates.  What are hp, bhp and botu? Reference Basic Electrical Engineering by ML Anwani, Gupta and Mehta
12 CHAPTER V: OHM’S LAW Series, parallel circuits, comparisons OHM’S LAW The Ohm‟s Law was propounded by George Simon Ohm, which defines the relationship between current (i), power (p), voltage (v) and resistance (r) I = v / r - 1 r = v / i - 2 v = i x r - 3 Ohm‟s Law states that, in any closed electrical circuit the current is directly proportional to voltage applied and universally proportional to the resistance of the circuit, temperature and other physical conditions being constant. CIRCUITS AND CONNECTIONS Introduction Line supply comes from power sources and terminates at the switch and distributed to the light points. The whole process ends with a circuit. Aim To understand various circuits and connections Teaching and learning methodology Theory, demonstration, practical and chart Objectives After completion of this session the aspirant should be able to:  Define what is an electric circuit  Understand various types of circuits  Compare Series and Parallel connections  Draw a circuit diagram and solve simple calculations Definition of circuit The path taken by an electric current is called a circuit. Circuit Components  Power source (AC / DC)  Current carrying conductor (wire)  Mechanism/ controller (switch)
13  Resistance or load (consumer) Types of Circuits  Open circuit  Closed circuit  Short circuit  Leakage circuit Connections Circuits are connected in two ways: Comparison between series and parallel: Series connection Parallel connection 1. 1. 2. Current flows in single path 2. Current flows in several paths 3. Voltage is divided across each resistance v = v1 + v2 + v3 3. Voltage is constant 4. Current is constant 4. Current is divided i =i1+i2+i3 5. Total resistance is equal to the sum of individual resistance r = r1 + r2 + r3 5. The reciprocal of the total resistance is equal to the reciprocal the sum of individual resistance i.e. 1/r = 1/r1 + 1/r2 + 1/ r3 6. Fault finding is difficult 6. Fault finding is easy 7. Used for decoration purpose 7. Used for domestic purpose Note: Practical related to Series and Parallel Review / Assessment  Definition and types of circuit  Circuit components  Series and Parallel connections  Short circuit Reference Basic Electrical Engineering by Mehta Skill Making series and parallel connections Parallel connection Series connection
14 CHAPTER VI: CONDUCTORS AND INSULATORS Introduction, Types, Materials, Wires, Guages Cables Introduction Conductors and insulators play a vital role in domestic / industrial wiring, including networking systems. While conductors carry the current, insulators provide safety for it. It is important to understand them well. Aim To understand conductors and insulators Teaching Learning Methodology Lecture, Demonstration and Practical Learning Objective After completion of this lesson the aspirant would be able to  Define a conductor and an insulator  Differentiate between a conductor and an insulator  State the materials used for a conductor and an insulator  Understand the properties of a conductor and an insulator and their uses Preview Conductor: A material which contains many free electrons and is capable of carrying electric current is known as a conductor. Properties of a conductor: Conductors:  Have a law specific resistance  Are mechanically rigid  Should be easily available  Should not be very expensive  Should be non corrosive  Should be ductile  Should be durable, malleable  Should have high stencil power  Should be highly conductive The common conductors used for electrical purpose are:  Silver  Copper  Bronze  Brass  Aluminum  Lead  Tin  Micromere  Tungsten  Eureka  Carbon etc. Insulators: A substance which cannot pass current through it under normal conditions is termed as an insulator. Properties of insulators: Insulators:  Should have low conductivity  Should have a high specific resistance  Should have a resistance and ability to bear high temperatures  Should have a good mechanical strength  Should be moisture resistant and water proof  Should have a high dielectric strength (voltage bearing capacity)
15  Should be permanent in nature (remain in the same state and condition regardless of the environmental conditions) The common insulation used for electrical uses:  Bakelite  Porcelain  Mica  Rubber  Fiber  Vanish  Glass  Wood  Cotton tape  PVC  Oil Classifications of cables according to the insulator used:  VIR wires  PVC wires  Flexible wires  Enameled wires  Cotton covered wires Conclusion Conductors and insulators are not only used for electrical wires but also for power generation, transmission and distribution system. Assessment / review  Define the conductor & insulator  Properties of conductor & insulator  Name different conducting & insulating materials.  Classify the cables according to the insulation use? o VIR, CTS o PVC Reference Basic electrical engineering by Mittal UNDER GROUND CABLES Introduction Electric power can be transmitted or distributed either by OHL or by underground cables. The underground cables have several advantages, the only disadvantage being the initial cost. Aim To facilitate learning about underground cables Teaching and Learning Methodology Lecture, demo and Practical Session Learning Objective After completion of this session the aspirant would know about: a. Construction of cables b. Classification of cables c. Cables used for 3 phase service d. Laying of underground cables
16 Preview Underground cables An underground cable essentially consists of one or more conductors covered with suitable insulation and surrounded by a protecting cover. Construction of cables The various parts of underground cables are as under as shown in the picture. a. Cores or conductors b. Insulation c. Metallic sheath d. Bedding e. Armoring f. Serving Insulating material for cables The satisfactory operation of a cable depends to a great extent upon the characteristics of insulation used. The principal insulating materials used in cables are: a. Rubber b. Vulcanized Indian Rubber (VIR) c. Impregnated paper d. Varnished cambric e. Poly Vinyl chloride (PVC) Classification of cables Cables for underground service may be classified in two ways according to: 1. The type of insulating material used 2. The voltage for which they are manufactured According to the voltage 1. Low tension (LT) cable – up to 1000V 2. High tension (HT) cable – up to 11,000V 3. Super tension (ST) cable – up to 33 KV 4. Extra high tension (EHT) cable – 3 KV to 66 KV 5. Extra super voltage cable – beyond 132 KV Cables for 3 phase service 1. Better cable – up to 11 KV 2. Screened cables – 22 KV to 66 KV 3. Pressure cable – Beyond 66 KV
17 Laying of underground cables 1. Direct laying 2. Draw in system 3. Solid system Review 1. How do you classify the cables? 2. What are the types of cables used for 3 phase system? FAQ 1. What is EHT, EST? 2. Explain the methods of cable laying? Related skill Cable jointing Reference Principles of power system
18 CHAPTER VII: ELECTRICAL ACCESSORIES Switches, Sockets Introduction Electrical appliances occupy a prime place of importance in our life style. The usage of electricity in modern life is increasing the standard of living in almost every home. On the other hand, Electrical wiring, which is essential for these appliances to work, receives very little attention. As an electrical technician, contractor, consultant or architect we are responsible to both the builder and consumer. The reputation and success of technicians depends on the quality of wiring they door recommend. Teaching and Learning Methodology Lecture Method, Demonstration and Site visit Aim To impart knowledge and related skills to the aspirant Learning Objective At the end of this session the aspirant will know about the: a. Protection and distribution of supply system and accessories used b. Cable carrier and support system c. Different types of current carrying conductors d. Switching and terminating products e. Sensor switching etc. Preview House wiring accessories can be classified into the following categories: a. Control and distribution system b. Cable carrier and support system c. Current carrying conductors (wires) d. Switching and termination products e. Sensor Switches a. Control (Protection) and distribution system This system is used to control the main supply and distribute it to the circuits. The main protective devices used in house wiring circuits are: i. Fuses (Fuse that can be re-wired, HRC Fuses available at diff ranges [6Amp to 200Amp]) ii. ICDP, ICTP (available at 32A to 200A) iii. Miniature Circuit Breakers (available at 1A to 40A) iv. Isolator (available at 32A to 63A) v. ELCB / RCCB – (available at 32A, 40A & 63A) and MCCB above 63A All the above mentioned items are installed in control and distribution boards. The Boards are available in 1 phase, 3 phase, single door and double door as shown in the picture. b. Cable carrier and support The house wiring cable can‟t be run or laid on walls without support. Hence the wires need to be supported from the main distribution till the terminating product. The systems used to carry, support and run these wires are called cable carriers and support systems. The different systems which we adopt for the same are as follows: i. Wooden capping & casing wiring
19 ii. Cleat wiring iii. Conduit wiring (open/ surface) iv. Conduit wiring (concealed) c. Different accessories available to carry wires i. PVC conduits available in 19 mm, 25 mm ii. Junction Box – 1 way, 2 way, 3 way and fan hooks iii. MS / GI conduits and its accessories such as MS inspection bend, Inspection „T‟ and „J‟ boxes etc. iv. The conduits are available in sizes of 16mm, 19mm, 25mm and 30mm and are normally of 16 SWG thickness v. Casing and capping batten patties are also available in different sizes for temporary wiring vi. House wiring cables (current carrying conductors): The cables are used to carry the current from main supply to the sub circuits or to a particular point. Earlier house wiring cables used tinned copper conductors covered with Vulcanized Indian Rubber (VIR) and CTS also called TRS. vii. House wiring cables and their historical back ground: Till 1955 : VIR – CTS cables are most commonly used for outdoor and indoor purposes 1955 : Introduction of PVC Cables as per IS-694; India started to manufacture PVC Cables indigenously 1991 : BIS started giving certification under IS 694 to copper cables viii. Common cables used for house wiring ISI recommends the use of metric system of wires as given below: a. 1.0 Sq mm b. 1.5 Sq mm c. 2.5 Sq mm d. 4 Sq mm e. 6 Sq mm f. 10 Sq mm Note: Obsolete British standard cables are 1/18, 3/20, 7/20 etc. d. Switching and terminating products All these products have certain common features like insulation bases and covers. All the house wiring cables normally terminate in: i. Switches (All types) ii. Sockets iii. Ceiling roses iv. Holders and adaptors etc. i. Switches: Switches are classified as under: 1. According to the rating – 6 A, 10 A, 16A 2. According to the connection – 1 way, 2 way and intermediate ii. Sockets: 1. According to the rating: 6A, 10A, 16A, 25A etc. 2. According to the connection: 2 pin, 3 pin, 5 pin, multi pin etc. iii. Ceiling Roses: The wiring from switch terminals is taken to ceiling roses, lamp holders and connectors. The ceiling roses are available in two types. These are 2 pin and 3 pin. iv. Holders and Adaptors: There are some other terminating products named as holder and adaptors.
20 Different holders are available in the market: a. Angle Holder b. Batten Holder c. Pendent Holder d. Screw type / Pin type Holder etc. e. Sensor Switches: Sensor switch is also similar to the switch but it works on sensor signals. It is a small electronic circuit. The sensor switches are as under: a. Temperature sensor b. Light sensor c. Dark sensor d. Sound sensor e. Acoustic sensor f. Vibration sensor g. Altitude sensor h. PIR (Passive Infrared) etc. Personal safety and Earthing: Earthing is the most neglected aspect in house wiring and is usually considered an unnecessary expenditure. However, Earthing is the most essential safety requirement. Providing good earthing is a basic need as per Indian electricity rules under IS 3043, 1987. Electrical contractors, Electricians and wire men should ensure that they do not compromise on the safety of their clients or clients‟ families. (Earthing lesson has been covered on the video) Standby power sources: Power outages are very common in all parts of the country which is why standby power sources are very essential to fulfill the power shortage. Standby power sources may be: a. Alternators / Generators b. UPS (Uninterrupted Power Supply) system c. Inverter d. Emergency lights etc. Security and protection: Security of house hold property and lives of the residents is increasingly becoming a matter of concern. We hear of many instances where criminals have forced their entry and ransacked houses. There is, therefore, a growing need for equipment which will improve the safety and security of life and property. There are several effective alarming systems available in the market (burglar alarms, smoke detectors etc.) which are usually not preferred by the common man due to their heavy costs. Review / Assessment  Name different control and distribution system?  How can wires be carried and supported?  What are the various terminating products available in house wiring systems?  What are the different conductors used for house wiring systems?  What are the uses of sensor switches? FAQ 1. What are the different sources available for standby power? 2. What is the need for security and protection systems? Reference Hand Book ICPCI
21 CHAPTER VIII: WIRING SYSTEM Tpyes, Testing, Earthing, Distribution DIFFERENT TYPES OF WIRING SYSTEMS Introduction The good appearance of a house depends upon the house wiring system adopted and selection of branded material. Thus is the need to know about quality of the wirings and accessories being used. Teaching and Learning Methodology Lecture, Demonstration and Practical Aim To discuss about the different system of wiring Objectives After completion of this session aspirants would know about  Criteria for selecting a particular type of wiring  Customer expectations  Providing customer satisfaction  Factors that are to be considered in house wiring Preview Criteria for selecting a particular type of wiring The following points must be considered before selecting a particular wiring. 1. Durability: The wiring must be able to withstand wear & tear under any circumstances. 2. Safety: The wiring must be able to provide safety by safely concealing the wiring systems. 3. Mechanical Protection: Conduit wiring must be protected from damage through physical or natural changes during its use. 4. Appearance: Appearance is the most important aspect to consider from the architectural point of view. 5. Permanency: The wiring must not be affected by weather, smoke, dampness etc. 6. Accessibility: In the wiring system facility for the extension or renewal or attraction should provided. The wiring must be done in a way that makes distribution of power easy, without any hassles. 7. Cost: The wiring system adopted must be economically suitable to the client. Customer Expectation As technicians we must be able to predict a customer’s expectations such as  Reduction in electricity bills  Safety against electrical fire hazards  Good Earthing to avoid electric shocks  No hanging of „wire webs‟ in the house  Proper concealed wiring  No extension boxes and wires  Hassle free wiring How to provide Consumer Satisfaction Customer satisfaction can be provided by the following  Adequate number of points (comfort and safety)  Circuitry design (Safety, No over-loading)  ISI Mark ETP wires (Reliability, Safety, multi strand flexible wire, energy saving)  Higher cross sectional area of wire (Safe and energy saving)
22  Derating factor (cables are derated to have the capacity to take more current than usual, i.e. one-size-up cable) – due to concealed wiring  Earthing with Copper wire(Safety against shocks) Common factors considered in house wiring  Cable selection (Voltage grade and Voltage drop, Current rating etc.)  Over loading  Circuitry design  Short circuit  Earthing  Derating etc. Specification of wiring Lighting loads (Bulb, Fans, and Fuses etc.) Medium loads (T.V., Refrigerator, Iron boxes etc.) Heavy loads (A/C, Geyser, Electric Cooker, Washing Machine etc.) Conclusion Show Video Review / Assessment 1. What are the points to be considered before going for any particular wiring? 2. How do you fulfill the customer‟s requirement? 3. What are the different factors that are to be considered before going for any type of wiring? FAQ 1. How do you specify the wiring system? 2. How many types of loads are there? 3. How can you specify the wiring system? Reference House wiring hand book (ICPCI) Skill Wiring for Staircases, Hotels, Godowns etc. Drawing Room Bed Room Kitchen Bathroom 4 Sq mm Main Distribution Board 4 Sq mm 4 Sq mm 6 Sq mm Main Distribution Board Meter
23 HOUSE WIRING, CONDUIT PIPE WIRING Introduction There are a number of wiring systems that are used in the construction of a building. However, nowadays every customer prefers conduit wiring –especially concealed conduit – because it suits the requirement and expectations of the customer. So we discuss about conduit house wiring system. Teaching and Learning Methodology Lecture, Demo and Practical session Learning Objective After completion of this lesson an aspirant will be able to explain: a. Advantages of conduit wiring b. Precautions to be observed during wiring c. Instructions for conduit pipe wiring d. ISDRTE Rules regarding wiring Preview Uses Open conduit: Godowns, Cinema halls, workshops. Concealed conduit: Domestic, Industrial, Software layouts Advantages of conduit pipe wiring  It has good mechanical strength  It is almost all fire proof. It is fire proof  It is fairly water proof  Mechanical thrust and pressure does not affect the wiring  It is fire proof even when short circuit occurs  The defective wires can be easily replaced  Finding the fault is easier  We can run additional wires whenever Necessary Dis-advantages  It is expensive  Its installation requires skilled and experienced persons Precautions:  The earth wire should be run within conduit  The water or gas should be away from the conduits  The conduit pipes should be cut properly  The conduits ends should not be sharp in order to not tear the insulation of the wires  Guide wire or house wiring spring should be used while wiring  Proper gauge of conduit pipes grip fittings must be used  Conduits must be run according to the circuitry planning ISI Rules Indian Standard Instructions rules regarding various wiring systems are as follows:  Ensure maximum eight loads in a circuit  The switch, MCB / Fuse should always be installed on the phase line  All main switches should be covered with an iron sheet or insulating material sheet  Every thicker pin of socket must be connected with earth wire  The three phase power should be marked in Red, Yellow and Blue  Danger caution board should be hung near main switches that are above 250 Volts  A ceiling fan should be installed at a height of 2.7 to 3.18 m, from the floor  Ensure independent circuits for each room  The power loads and lighting loads should be distributed and connected separately
24  The main switch board and lighting switch boards should be connected at a height of 1.5 m from the ground  The wires used must be of higher cross sectional area to ensure smooth flow of current  40% of the conduit must be empty while running the cables Check list for electrical wiring  Number of points in each room as per the drawing and requirement  Location of the points  Height of the boards from the floor  Quality and specifications of the material being used  Sizes of the boards  Internal connection of main boards and phase switch  Codes and sizes of wires used  Earthing connection  Mains for correct voltage etc. Review 1. What are the factors to be considered before the wiring? 2. Write the different ISI rules related to the house wiring? FAQ 1. At what height (from the floor) should the ceiling fan be fixed? 2. List down the components of the check list for the electrical wiring? Reference Basic electrical engineering by Gupta Skill Surface conduit, concealed conduit DIFFERENT CONDUCTORS USED FOR HOUSE WIRING SYSTEM Introduction The conductor of a cable is like the heart of the human body. The function of the conductor is to carry current, like the heart circulates blood in the body. If the blood circulation is irregular and improper, it may cause various diseases in the body. Similarly if the conductor (copper) is not good, due to reasons like impurity of copper or improper bunching, the current carrying capacity of the conductor will reduce. So we need to use good conductors. Objective After completion of this lesson an aspirant will be able to explain the following: a. Classifications of conductors b. Latest trends in house wiring cables c. Selection of cables and their criteria d. Abbreviations used Teaching and learning Methodology Lecture, Presentation (PPT), Demo and Practical session Preview
25 Types of wires used in domestic and industrial wiring are classified as under: According to the core  Single core wire  Two core wire  Three core wire  Four core wire According to insulation (Stand wires)  VIR wire  CTS or TRS wires  PVC wires  FRLC  HFFR  Weather proof wires  Enameled wire  Fire resisting etc. According to the metal  Bare Copper  ACSR Conductor  Fuse wire  Nichrome wires Latest trends to meet present scenario Looking back in history, we come across many accidents like the incident of “Upahar Cinema Hall” (Delhi) which took lives of 175 people due to breathlessness (suffocation) caused because of fire and dense black smoke. The victims could neither see nor be seen by others and thus could not be rescued in time. Fire hazard cables: Keeping the above draw backs in mind we have latest trends in cables such as  FRLC  HFFR  FIREX etc. The main criteria for selection of Cables  Voltage grade for house wiring  1100 V, 1.1 KV grade  Current rating of cables  Voltage drop in cables on current flow  Short circuit withstanding capacity  Derating or safety load etc.  Avoid using obsolete British standard cables such as 1 / 18, 3 / 20 etc.  ISI recommends the use of metric system such as, 1.5 sq mm, 2.5 sq mm, 4 sq mm, 6 sq mm, 10 sq mm Characteristic Normal PVC FRLS PVC Oxygen Index 23 29 Temp. Index 160°C 250°C Acid Gas 40% by Wt 20% by Wt Smoke Density >80% < 60%
26  Flow color codes for wiring (as shown in the picture) o Green – Earthing o Black – Neutral o Red, Yellow, Blue – Phases Abbreviations CTS : Cab Tire Sheathed VIR : Vulcanized Indian Rubber PVC : Poly Vinyl Chloride ETP : Electrolytic Tough Pitch FRLS: Fire Retardant Low Smoke HFFR : Halogen Free Flame Retardant Conclusion There is a need to give examples of many case studies, conventional cables and fire retardant cables to the aspirants. Technicians should recognize the quality of a conductor by seeing it. Review a. How do you classify the cables according to insulation? b. Which are the new cables available in the market used to avoid electric shocks? c. What are the criteria to select a cable? FAQ Write the full forms 1. CTS, VIR, PVC, ETP? 2. FRLS, HFFR? Reference General Information Related Skill  Wires and joints  Routing diagram of single and three phase systems  Laying of conduits on slab  Chipping, laying of conduits and wiring at live sites
27 CHAPTER IX: ELECTRICITY Sources, Effects, Uses HISTORY AND BASICS OF ELECTRICITY Introduction Although man has been aware of electricity for several centuries, a proper scientific understanding of it began only in the 18th century. In this session, we will learn about the history of electricity and its basics. Aim To understand the history and basic of electricity Objectives After completion of this class the aspirant should be able to understand the following:  History of electricity  Sources of energy  Law of conservation  Definition of electricity History of Electricity  Around 600 BC,Thales, a Greek philosopher, discovered frictional electricity.  In 1600 AD, William Gilbert, an English physicist, coined the word „electrical‟ (Latin word derived from the Greek word electron.  In 1646, Sir Thomas Brown, an English writer, modified the term to „electricity‟.  In 1800, Alessandro Volta, an Italian scientist, discovered a chemical form of producing electricity.  In 1831, Dr Michel Faraday, an English scientist (also known as the „father of electricity‟), discovered dynamic electricity with electromagnetic Induction. He is also called as the ' father of the electricity.' The Law of Conservation of Energy The Law of Conservation of Energy states that energy cannot be created or destroyed; it can only be changed from one form to another. Sources of Electrical Energy Water, Sun, Coal, Fuels, Nuclear, Wind Review  Who invented electricity and chemical electricity?  What is the source of electrical energy?  Define the law of conservation.  What is electricity?  Who is regarded as the father of electricity?  When was dynamic electricity invented? Reference Basic Electrical Engineering by M L Anwani
28 PRINCIPLES OF ELECTRICITY Introduction Electricity has become an integral part of our lives. It is essential for lighting, power, air conditioning, refrigeration and a host of other applications. Life without electricity is almost unimaginable. We must therefore have a fair knowledge of the principles of electricity. Aim To introduce the principles of electricity Teaching and learning material Lecture, charts and role play Objectives After completing this class, you should know the following:  What is electricity?  Current, voltage, resistance and units.  Ohm‟s law and the relationship between current, voltage and resistance.  Types of electricity. What is electricity? Electricity is an invisible and untouchable form of energy. But it can felt through its effects. The components of electricity are current, voltage and resistance. Current Current is defined as the free flow of electrons through a conductor, which is measured by an Ammeter, measuring unit is Amps and letter represented by I. Voltage Voltage is an electrical pressure required to drive free flow of electrons through a conductor. It is measured by a voltmeter; measuring unit is volts and letter represented by VorE. Resistance Resistance is the property of a material which opposes free flow of electrons through it. It is measured by an ohmmeter; measuring unit is ohms and letter represented by R. Ohm’s law The Ohm‟s Law was propounded by George Simon Ohm, which defines the relationship between current (i), power (p), voltage (v) and resistance (r) I = v / r - 1 r = v / i - 2 v = i x r - 3 Ohm‟s Law states that, in any closed electrical circuit the current is directly proportional to voltage applied and universally proportional to the resistance of the circuit, temperature and other physical conditions being constant. Review  Define current, voltage and resistance.  What is Ohm's Law?  What is use of Ohm's Law?  Name the different units used in electricity. Reference Basic Electrical Engineering by ML Anwani
29 EFFECTS OF ELECTRIC CURRENT Introduction As we discussed earlier, electricity is an invisible form of energy that can be perceived only through its effects. Whenever current flows through a conductor, it is actually electrons flowing from one place to another. It is not possible to see the electrons or current flow. So it is essential to know about the effects of electric current. Aim To gain an understanding of the effects of electric current Objectives At the end of this lesson you should be able to:  Understand the effects of the electricity.  Explain each effect  Do experiments and demonstrate each activity. Effects of Electricity  Physical effect: The human body is a good conductor of electricity. So when we touch an object through which current is flowing, we get a shock. Severe shock may even lead to death (examples through case studies, activity, etc.)  Heating effect: Whenever current passes through any conductor, heat is produced in that conductor. Such effect is used in a heater, press, lamps, soldering iron, etc. (activity based experiment)  Magnetic effect: This effect is seen in fans, meters, calling bells, etc. (demonstrate a calling bell)  Chemical effect: When current passes through an electrolyte, a chemical reaction takes place. Battery charging and electroplating are good examples.  X-ray effect: When high frequency is passed through a vacuum tube, a special type of high-penetration rays come out, which cannot be seen. They are called x rays; they are used to take images of the insides of our body to diagnose diseases and determine treatment. Review  What are the effects of electric current? Explain each one of them.  How are x-rays produced? What do they do? Reference Basic Electrical Engineering by ML Anwani
30 CHAPTER X: AC / DC / POLYPHASE Basics, Differences, Connections, Comparisons, Advantages SINGLE PHASE INDUCTION MOTORS Introduction The construction of the single phase motor is similar to the poly phase induction motor with an exception that the stator has a single winding. So the stator field produced is only alternating instead of starting like in a poly phase system. That is why single phase motor is not self starting. Aim To facilitate knowledge / skills transfer related to single motor Teaching and Learning Methodology Lecture, demo and role play Learning Objective After completion of this session the aspirant shall be able to know: a. Classification of single phase motors b. Construction details of each motor c. Characteristics etc. Preview Classification According to the starting of AC devices, single phase can be classified as following: 1. Split phase motor: a. Plant split single phase motor b. Capacitor start induction runs motor c. Capacitor start, capacitor run d. Permanent capacitor motor e. Shaded pole motor 2. Repulsion motors: a. Plant repulsion b. Repulsion start induction runs motor c. Repulsion induction motor 3. Universal motors: Characteristics of single phase motor: 1. Starting current is high 2. Starting torque is low which increases with load 3. Constant speed but slightly falls with increase in load 4. Power factor is low 5. Maintenance cost is high Split phase single phase motors are used for lathe machines, drill machines etc.
31 Capacitor motors Capacitor motors are used for Refrigerants, Compressors, Cloth washing machines, Printing press, Drilling machines, Lathe machines etc. Parts of capacitor motors As shown in the picture (on the right), there are five parts. Those are: 1. Rotor i.e. moving part 2. Stator i.e. static part 3. End covers 4. Centrifugal switch fitted inside 5. Capacitor which is connected in series with the starting winding Review 1. Name the different types of single phase motors? 2. What are the different parts of capacitor motors? 3. Explain different characteristics of AC phase motors? FAQ Which voltage of single phase motor? Reference Basic electrical engineering by Mittal Mehta, M.L.Anwani, Gupta etc.
32 CHAPTER XI: GENERATORS AND MOTORS Principles, Parts, Uses, Functioning, Starters, General Maintenance AC MOTORS Introduction The electric motors are the most common appliances / gadgets used in a day. In addition to the other fields, Electricity also plays a vital role in Agriculture. AC motors is a very wide class of motors, which includes single phase, poly phase, universal, servo, Induction synchronous motor etc. Aim To impart the knowledge and skills related to AC motors. Teaching and Learning Methodology Lecture, Demo and site visit. Objective Upon completion of this lesson the aspirant would be able to a. Define and explain the working principle of AC motors b. Explain the construction details of AC motors / classification c. Practice maintenance, troubleshooting and installation Preview 1. What is an AC motor? A motor is a device which transforms the electrical energy into mechanical energy. AC motors are used worldwide in many residential, commercial, industrial and utility applications. The stator of an AC motor is similar to the stator of a rotation field type of alternator. 2. Working principal of induction motors AC is supplied to the rotor, which produces a rotating magnetic field. This field causes the rotor of the motor to rotate. As the rotor rotates it cuts the magnetic field produced by the stator and an EMF is induced in it. Principle When a short circuit conductor is placed in a rotating magnetic field, the conductor tends to move. 3. Classification of AC motors AC/DC According to the working principle a. Synchronous Motor i. Plain synchronous Motor ii. Auto Synchronous Motor b. Asynchronous Motors I. Three phase induction motors i. Squirrel cage induction motor ii. Slip ring induction motor iii. Commutator motor II. Single phase induction motors i. Split phase induction motor ii. Capacitor induction motor iii. Universal induction motor iv. Shaded pole induction motor
33 v. Repulsion induction motor According to the phase a. Poly phase motor b. Single phase motor According to the speed a. Constant speed motor b. Variable speed motor c. Adjustable speed motor According to the construction a. Enclosed type motor b. Semi enclosed type motor c. Open type motors d. Reverted type motor e. Ventilated type motor Construction Construction of 3 phase, 1 phase motor parts are as follows: a. Stator b. Rotor c. End cover d. Bearing e. Fan Common Troubles and Repairs The symptoms encountered and their possible outcomes, in defected 3 phase motors are as listed below. 1. If motor fails to start The troubles may be:  Burned out fuse  Worn out bearings  Overload  Open Phase  Shortened coil  Loose rotor bars  Wrong general connection  Frozen Bearing  Grounded winding  Defective controllers 2. If the motor runs slowly The troubles may be  Shortened coils / groups  Reversed coils / group  Worn out bearings  Overload  Wrong connection, Reversed phase  Loose rotor bars Installation Electrical machines and apparatus should always be installed where:  They can get adequate ventilation and clean dry air  They should be accessible for full inspection and repairs  The machine is erected on solid and vibration free foundations  The motor is anchored by means of foundation studs  The machines is always carefully aligned  The slide rails house the screws in opposite directions
34 Note: A site visit, practical session on dismantling and constructing etc. Latest trends Energy efficient motors Conclusion An electrician has to do the erection work also. At most of the places the motor should be kept 8 or 10 cm above the floor. Electricians must be up-to-date with the latest trends in the market. Review 1. What is an AC motor and how does it work? 2. How many types of AC motors are there? 3. Name the single phase motors? FAQ 1. Name the parts of an AC motor? 2. What are the common troubles that arise? Reference AC Machines - Mehta
35 DC GENERATORS Introduction Energy is the basic necessity for the economic development of a country. There was no power generating system in the olden days. Later a new generation of power was started in the form of DC generators then they were modified to have increased efficiency and called as AC generators or alternators. Aim To make the aspirants familiar with a DC generator Teaching Learning Methodology Lecture, Demonstration and Site visit Learning Objective After completion of this lesson an aspirant would be able to: a. Define a generator and explain its working principle. b. Explain construction details of DC Generators. c. Classify DC generator. Preview DC Generator DC generator is a machine which converts the mechanical energy into DC electrical energy. Working Principle According to Dr. Faraday‟s Law of Electromagnetic Induction, the conductor (armature) is rotated in the magnetic field system and EMF is induced in that conductor, which is collected from the commutator fitted on the shaft of armature. DC generator can work as a DC motor, when electrical power is fed to the machine. Construction Details The different parts of a DC generator are as under: a. Yoke or body b. Pole core and pole shoe c. Armature d. Commutator e. Brushes and bearing f. Field coils Note: Explain about each part in detail Types of DC Generators DC generators are classified according to their field. They are of two types. 1. Self excited generator 2. Separately excited generator. 1. Self excited Generators are those, whose field magnets are excited by themselves. There are again three types of self excited generators. a. Serious wound Generator b. Shunt wound Generator c. Compound wound Generator Compound WOUND generators are further classified into two ways: i. Short shunt compound wound generator ii. Long shunt compound wound generator
36 Conclusion DC generators are not economical and AC generator are replaced them in present days. Review / Assessment 1. What is a DC generator and how does it work? 2. Name the parts of a DC generator? 3. What are different types of a DC generator? FAQ: 1. Function of commutator 2. Function of carbon brushes Reference Basic Electrical Engineering by Mittal & Mehta. Practical Site visit AC MOTOR STARTERS Introduction If an induction motor is directly connected to the 3 phase supply, it would draw a full load of current. However, since the motor is not running this heavy flow of current may damage the motor windings as well as the line. In order to decrease the staring current a starting device is used with the motor, which is known as starter. The starter reduces the starting voltage and hence the starting current. Aim To impart knowledge and skills related to the starters. Teaching Learning Methodology Theory, Demonstration and Practical Session Learning Objective At the end of this class the aspirant would be able to: a. Define the starter b. Explain about different starters used for different purposes c. Know about functions of protective device d. Explain construction and functioning of each starter e. Draw the circuit diagrams of each starter Preview Starter Starter is a device used to start the AC motors, safely and to minimize the starting current to protect the motor from load and high voltage. Types of starters The different starters used for the purpose are as follows: 1. Direct online starter (DOL) 2. Star Delta starter i. Manual semi delta starter
37 ii. Semi Automatic delta starter iii. Fully automatic delta starter 3. Auto: Transformer type starter 1. Direct Online (DOL) Starter It is a simple and ordinary starter, suitable for squirrel cage induction motors that have a capacity up to 5 HP. It does not reduce the voltage. It is sufficient to connect the motor from the line ICTP / Main switch / Isolator. The DOL starter has the following advantages: a. The motor can be switched on and off quickly. b. It cuts the motor from the line one over loads. c. It prevents the motor from burning on single phase.  Mainly DOL starters consist of contact system thermal relay units and a solenoid coils.  The contact system consists of silver tipped contacts, which provides a quick on – off system.  Thermal relay bimetallic elements protect the motor from over load.  The solenoid coil or no–volt coil is connected across the two phases. (Phase and neutral in case of single phase)  On pressing the start button the solenoid coil becomes magnetized and it attracts the iron, plunger, which closes all the contact points.  In this way L1, L2 and L3 are connected to the motor terminals M1, M2 and M3 and the motor starts running, as shown in the picture above. Push buttons are used in place of the handles. The green push button starts the motor, while the red push button switches off the motor. A latch fitted near the red push button can be adjusted over it, so that motor may not be started. Protective Devices No–Volt Coil (NVC) and Over Load coil Relay (OLR) are provided in a start delta starter as protective devices. No–Volt Coil (NVC) [Ref Figure given below] It is an electromagnetic coil made of fine copper wire. The NVC is connected to B2 and A2 terminals. These terminals get supply from L1 to L3 respectively in the run position. If the supply fails, the motor becomes over loaded, then the NVC will be demagnetized and will release the handle, thus the motor will be switched off. Over–Load Relay It consists of three bi-metallic strips, which get bent in one direction, above a pre-set temperature. The bending of these strips disconnects the NVC, which will leave the hands of
38 the starter to off position. Each strip is connected in series with a phase line. The leaver of the OLR dial is set in such a position that the tripping will occur at about 25% over load current. Star Delta Starter This starter is fitted in 5 HP to 10 HP motors. In this starter there are two way switches which connect the six ends of the motor once in star and then in delta. It also has OLR, No-volt coil, current adjuster and off switch like the DOL starter as shown in the picture. Auto-Transformer Starter A starter of this type is used in up to 25 HP motors. This type of starter has an auto – transformer from which many tapings are taken out which give different voltages by which a big motor can be supplied with low voltage, while in the Star Delta Starter only 13 times the full voltage can be given to the motor. The torque also varies with the voltage. It also has OLR, NVC and off switch as per the diagram. Some other starters are also available like resistance type starter, auto starter etc. Common faults that occur  The starter of a slip ring motor has short circuit defect  The starter of a slip ring motor is earthed  The contact points of the starters remain in open circuit  The No–volt coil is not functioning  The Over Load Relay coil is defective  The starter connection is wrong Latest trends Automatic starters Review / Summary a. What is a starter and why is it necessary? b. How many types of stares are there? c. What are the common faults occurs in starters? FAQ a. NOC b. OLR c. DOL d. Star delta Skill Connecting DOL, Star delta starters to the motor and preparing a panel board.
39 CHAPTER XII: TRANSFORMER Principle, Types, Parts, Cooling Methods, Maintenance Introduction Now a days AC system, Specially 3 phase (poly phase) system is most commonly adopted for generation, transmission and distribution, because it is economical and efficient. In India all generating stations and alternators are practically producing 11 KV/ 21 KV. Using the AC system, such power can be stepped up, transmitted and distributed to reach the consumers‟ point, keeping low cost and reduced size of conductor in mind. A transformer is a device which conveys power from the generating station to the consumers‟ point. Aim To teach about transformers Teaching and Learning Methodology Lecture, Demonstration Learning Objective After completion of this lesson the aspirant would be able to: a. Define and explain working principle of transformers b. Classify the different types of transformers c. Name the parts and draw the 3 phase transformers Preview Transformer The transformer may be defined as a static piece of electrical apparatus which converts electrical power from one circuit to another at the same frequency while changing the corresponding values of current and voltage. Working Principle The transformer works on the principle of Mutual Induction. Classification of Transformers 1. According to the magnetic core a. Core type b. Shell type c. Berry type 2. According to the voltage a. Step up transformers b. Step down transformers 3. According to the phases / winding a. Single phase transformer b. Three phase transformer 4. According to the power / usage a. Lighting / distribution transformer b. Power transformer
40 5. According cooling a. Self cooled b. Air force cooled c. Oil self cooled d. Forcibly oil cooled 6. According to the location a. Indoor transformer b. Outdoor transformer 7. According to the output: a. Auto transformer b. Instrument transformer Protection devices a. Conservator b. Breather c. Temp Gauge d. Explosion vent e. Pipes etc. Review / Summary a. Define „Transformer‟ b. Classification of a Transformer c. Discuss the appropriate site for Installation of a Transformer d. Name different protection devices used in a Transformer FAQ  Function of Breather  Primary Coil  Secondary coil Reference Basic Electrical Engineering by Gupta
41 CHAPTER XII: UPS Basics, Connections, Maintenance LEARNING OBJECTIVE To know about the UPS, types, its functions and maintenance of batteries. UPS (UNINTERRUPTIBLE POWER SUPPLY) It is an electrical apparatus, provides energy power to a load, where input power source fails. Typically it is used to protect computers, data centers, telecommunication equipment or other electrical equipment where an unexpected power disturbance could cause damage, fatalities, serious business disruption and/or data loss. FUNCTION OF UPS Primary role of UPS is to provide short term power, when the input power source fails. However, most UPS units are also capable in addressing in varying degrees of correcting common utility power problems like: 1. Power Failure: 2. Surge : Momentary increase in main voltage 3. Sag : Decrease in input voltage 4. Spike : Brief high in voltage excursion 5. Noise : Oscillation 6. Instability : Temporary change in mains frequency 7. Harmonic 8. Distortion : Departure from the ideal sinusoidal waveform expected on the line TYPES OF UPS Since UPS address a no. of problems so divided into categories based on which they address the problem; · ON-LINE UPS · LINE-INTERACTIVE UPS · STANDBY UPS (OFF-LINE) Online UPS Line interactive UPS Standby UPS
42 BATTERIES AND ITS MAINTENANCE Batteries are of various kinds may provide power for minutes, hours or days depending upon the electrical design. Usually it is flooded with lead-acid battery stalled in groups, several batteries are wined together in a series circuit forming o group providing DC electric power at 12V, 24V, 48V OR 60V (may be higher) , there are two or more group of batteries which are connected in parallel circuit. In a large scale set-up a separate battery room is there to house the batteries. Proper placement and maintenance of batteries are very important for shelf life of battery. Typical batteries may give hydrogen gas (H) so ventilation is critical otherwise it may cause explosion. There must be proper temperature maintenance because at high temperature life span of battery gets reduced and at low temperature energy storage capacity is reduced.
43 NAME OF EXPERIMENT Measurement of wire sizes LEARNING OBJECTIVE At the end of the exercise, the aspirant should be able to:  Skin the insulation of a cable  Measure the size of a wire using a wire gauge – in gauge no.  Measure the size of a wire using a micrometer CIRCUIT DIAGRAM TOOLS REQUIRED  Standard wire gauges 0-36 SWG - 1 no.  Electrician‟s knife - 1 No.  Combination‟s pliers - 1 No.  Manual wire stripper - 1 No.  Micrometer 0- .25 mm - 1 No. MATERIALS REQUIRED Material Specification Quantity Schneider products Cable pieces Cotton cloth 30 cm long each of size – 20, 18 , 16, 7/22 , 14/36 ,7/18 30x30cm Each one 2 pieces 2 No. PROCEDURE AND OBSERVATION TASK 1: Measuring the wire sizes by SWG 1. Skin the insulation of the cable 2. Clean the surface of the wire with a cotton cloth , remove insulation particles and any adhesive coating over the conductor surfaces 3. Straighten the end of the conductor to be measured 4. Insert the conductor in the slot of the wire gauge and determine the close fit slot 5. Read the marking at the slot, it gives the wire size in SWG. The other side will give the diameter of the wire in mm
44 OBSERVATION 1. Record the measured size in Table 1 TABLE 1 Sl.No Size SWG Diameter in mm 2. Repeat the measurements for all the cables included in material list SAFETY PRECAUTIONS Exercise care to prevent nicking and do not use any hand tool directly on the conductor for straightening.
45 NAME OF THE EXPERIMENT Prepare terminations - Skinning Cable ends LEARNING OBJECTIVE At the end of the exercise the aspirant will be able to  Identify the cutting tools such as an electrician‟s knife  Sharpen the electrician‟s knife , Combination‟s pliers  Skin (cut and remove) the insulation of cables using knife manual stripper- wire stripper with auto ejection CIRCUIT DIAGRAM TOOLS / INSTRUMENT REQUIRED  Electrician‟s knife 80 mm blades - 1No.  Wire stripper, manual 200 mm - 1 no.  Wire stripper auto – eject 150 mm - 1No.  Combination pliers 150 or 200 mm - 1 No.  Steel rule 300 mm - 1No.  Diagonal cutter or side cutting Pliers 150 mm - 1 No.
46 MATERIALS REQUIRED Assorted small sizes pieces required for practice PROCEDURE AND OBSERVATION TASK 1: Skinning cable insulation using knife 1. Mark the length of the 1.5 sq mm cable at 400 mm from its end 2. Cut the cable using combination pliers at the mark. 3. Mark the amount of insulation to be skinned from either end. 4. Check the sharpness of the knife blade and re- sharpen if necessary 5. Remove the insulation of the cable for about 10 mm at its ends using a knife. Keep the knife blade at an angle less than 45 to the cable. 6. Check there is no nicking over the conductor and cable is not shaved off. 7. Clean the surface of the bare conductor. 8. Cut the cable at the 12 mm from either end using combination pliers. 9. Repeat step No. 5 to 8, until the cable length is 350 mm. 10. Mark the insulation to be removed as in Fig 3 and repeat step No. 5 and 6. 11. Repeat the skinning of cable insulation of 2.5 sq mm cable, 14/0.2 mm, 48/0.2 mm, 23/0.2 mm, 80/0.2 mm and 128/0.2 mm flexible cables. 12. The length of the finished skinned cable should be of 300, 500, 600, 800, 1000 mm in each size. SAFETY PRECAUTIONS  While using this tool, make sure it is correctly adjusted before trying to strip the insulation from the cable without damaging the conductor and never use this tool to cut metallic conductor. Material Required Specification Quantity Schneider electric Products Aluminum cable of Following sizes Single strand cable 1/1.4 , 1.5 sq mm 3M - Single strand aluminum cable 1/1.8 ,2.5 sq mm 3M - Flexible cable Copper conductor 14/0.2 mm 23/0.2 mm 48/0.2 mm 80/0.2 mm 128/0.2 mm 3M 3M 3M 3M 3M - - - - -
47 NAME OF THE EXPERIMENT Making of simple twist joints LEARNING OBJECTIVE After completion of this exercise the aspirant should be able to  Mark the length of insulation to be removed  Skin the insulation  Prepare a straight twist joint  Prepare a rat –tail joint CIRCUIT DIAGRAM Fig 1 Fig 2 Fig 3 Fig 4 TOOLS /INSTRUMENTS REQUIREMENTS  Electrician‟s knife with two folding steel blades 75 and 100 mm - 1 No.  Steel rule 300 mm, stainless steel with graduations on either edge Cm/ mm and inches - 1 No.  Diagonal cutting pliers 150 mm with 660V grade insulated handle Suitable for cutting hard wires - 1 No.  Combination pliers 200 mm with 660 volts grade insulated handles With pipe grip, side cutter and two joint cutters - 1 No. MATERIALS REQUIRED Material required Specification Quantity Schneider Electric Product Insulated Copper cable 1/1.12 2M Insulated Aluminum cable 1/1.40 2M Cotton cloth 30 cm sq 1No. Paper “00” smooth 1 sheet
48 PROCEDURE AND OBSERVATIONS 1. Collect two pieces of 1/1, 12PVC copper cable of 0.5 m length. 2. Straighten the cables. 3. Mark 80 mm length on one end of each piece of the cable. 4. Use the knife at an angle of 20 as shown in Fig 2, and remove the insulation from each conductor for a distance of 80 mm. 5. Clean the ends with the help of cotton cloth. 6. Place the conductors together, about 50 mm from the ends. 7. Twist them tightly around each other in opposite directions. 8. Cut off the excess length of the conductor with side cutters. 9. Press the sharp edge of the conductor end and smooth it. 10. Cut off the joint after leaving 30 mm cable from the joint. SAFETY PRECAUTIONS  Pliers can be used to just grip the crossed conductors and each side to contain about 6 turns. Each turn of a conductor should fit closely to the adjacent turn.
49 NAME OF THE EXPERIMENT Making of tee joint in stranded conductors LEARNING OBJECTIVE At the end of this exercise the aspirant will be able to  Prepare a Tee joint in the given multi stranded conductors CIRCUIT DIAGRAM Fig 1 Fig 2 Fig 5 Fig 3 Fig 6 Fig 4 TOOLS/INSTRUMENTS REQUIREMENTS  Electrician‟s knife 75 and 100mm - 1 No.  Steel rule 300 mm - 1 no.  Diagonal cutting pliers 150 mm - 1 No.  Combination pliers 200 mm - 1No.  Wooden mallet 75 mm dia. - 1No.
50 MATERIALS REQUIRED Material Required Specification Quantity Schneider Electrical Product PVC Insulated copper Cable of 7/0.91,660V 0.5 M 2 PIECES Cotton cloth 30 X 30 mm 1 PIECE PVC Insulated aluminum cable 19/1.12 or 19/1.63 0.5M Sand paper “ 00 ”GRADE 25 sq cm PROCEDURE AND OBSERVATION 1. Collect two pieces of PVC insulated stranded copper cable 7/0.91.Indicate one piece as „through cable‟ and the other one as „tap cable‟. 2. Mark the point of tap in the „through cable‟ and mark 60mm on either side of the tap point for the insulation to be removed. 3. Remove 60mm insulation on either side of the „through cable‟ from the point of tap. 4. Remove the insulation for 180mm at the end of the „tap cable‟. 5. Open the strands of the „tap cable‟ and clean them .Use smooth‟00‟ sand paper, if necessary. 6. Re –twist the strands in the original direction upto 50 mm from insulation and make a binding on the twisted part of the „tap cable‟. 7. Untwist the „through cable‟ to provide an opening at the point of tap. 8. Insert the center strand of the „tap cable‟ in the opening of the „through cable‟. 9. Wrap 3 strands of the „tap cable‟ around the „through cable‟ on either side of the tap point. 10. Wrap the strands up to 50mm to leave a10mm between insulation and shoulders and trim the excess length of strands. 11. Remove the binding from the tap cable, wrap center strand of the „tap cable‟ around „through cable‟ and wrap it in the place of the binding. 12. Round up the ends with the combination pliers mallet to avoid sharp edges of the strands. 13. Collect two pieces of PVC stranded aluminum cable 19/1.12, or 19/1.63, 500mm long and repeat step 2 to12. SAFETY PRECAUTIONS  Do not nick or shave the conductor while removing insulation.
51 NAME OF THE EXPERIMENT Solder copper conductor joints LEARNING OBJECTIVE At the end of this lesson the aspirant should be able to  Solder copper conductor joints using a soldering iron and rosin-cored solder. CIRCUIT DIAGRAM TOOLS/INSTRUMENTS  Combination pliers - 1No.  Electric soldering iron 60W, 250V, 50Hz - 1 No.  File flat, bastard 150 mm - 1No. MATERIALS REQUIRED Material required Specification Quantity Schneider Electrical product Soldering iron with Cleaning pad 1No. Wire Brush 1No. Cotton cloth 30x30 cm 1No. Osin-cored solder 25gm Sand paper “00” GRADE 9Sheet PROCEDURE AND OBSERVATION 1. Select a60W, 230V AC 50Hz soldering iron and ensure that the iron has no physical damage the body is well insulated from the element and is of the correct voltage and power rating. 2. Surface of bit is to be smooth and clean. 3. Connect the soldering iron to the supply and switch it ON
52 4. When the bit becomes sufficiently hot ,apply a small quantity of rosin-cored solder, and tin the bit 5. Wipe the bit gently on the cleaning pad to remove excess solder. 6. Clean the joint to be soldered with the help of sandpaper “00”grade and wipe the dust. 7. Keep the soldering iron bit on the joint and heat it for soldering. 8. When the joint is heated, keep the rosin-cored solder on the joint and allow it to melt. 9. Melt the solder with the heat of the bit and make sure the solder flows freely and evenly on the joint. 10. Remove the soldering iron; wipe off the excess solder from the surface of the joint by cotton cloth, when it is still hot. 11. Let the joint to cool naturally. Do not blow air for cooling. SAFETY PRECAUTIONS  If the bit is not completely and evenly covered with solder, clean and tin it again.  Never flick excess solder off the bit .The hot solder may cause burn to someone or fall into part of the work ,and cause a short circuit.  A shining solder surface ensures a good soldering .Do not move the joint until the solder solidifies. Do not keep soldering iron on wood/plastic.
53 NAME OF THE EXPERIMENT Termination of cable ends LEARNING OBJECTIVE At the end of the exercise, the aspirant will be able to  Prepare the cable end for loop termination on screw terminal  Prepare a loop termination CIRCUIT DIAGRAM TOOLS REQUIRED  Steel rule 300mm  Electrician‟s knife  Wire stripper(manual)  Combination pliers 200mm  Screwdriver 100/150mmx4mm  Screwdriver 100mmx2mm  Long round nose pliers 150mm MATERIALS REQUIRED Material required Specification Quantity Schneider Electrical product Aluminum pieces + Copper cable 200 to 300mm As required Single conductor cable 1.5,2.5 sq mm As required Bare copper wire No 10 SWG 300mm Cable multi strand 14.02 mm As required PROCEDURE AND OBSERVATION 1. Take a single conductor cable of 1.5sqm of length 250 to 300mm. 2. Remove the insulation for the required length to make a loop. 3. Grip and turn the conductor with nose pliers. 4. Turn firmly gripped nose pliers to form required loop. 5. Repeat the same procedure for multi stranded wire also. SAFETY PRECAUTION  The loop should go at least about three quarters of the way around the screw and check the inner diameter of the loop with the terminal screw.  Never make the loop so long that the conductor can overlap. Keep the length of the exposed conductor to the minimum not more than 3mm to prevent accidental contact with other wires.
54 NAME OF THE EXPERIMENT Crimping of cable ends LEARNING OBJECTIVE At the end of the exercise, the aspirant will be able to  Skin the cable end  Select the pressure terminal( compression connector) that suits the wire size and the terminal size  Select the pressure pliers that match the pressure terminal size.  Use the crimping tool to crimp pressure terminal (lug) at the cable end. CIRCUIT DIAGRAM TOOLS REQUIRED  Pressure pliers200mm -01  Electrician‟s knife 100mm -01  Wire stripper (manual) 200mm -01  Combination pliers 200mm -01  Crimping pliers 150/200mm -01  Wire stripper auto-eject 200mm -01  Steel rule 300mm -01  Side cutting pliers 150mm -01  Eyelet closing pliers 200mm with -01 Former for eyelets having inner Diameter of 3, 4, 5, 6, 7mm
55 MATERIALS REQUIRED Material Required Specification Quantity Schneider Electrical Product Compression connectors Crimping eyelet, Eyehole 6mm(Diameter) 12 Nos. Crimping ferrule 4mm,10mm Long 6 No. Crimping Spade lug 6A 6No. Crimping Spade 10A,16A LUG 6No. Conductor or Pastes - 1 Tube PROCEDURE AND OBSERVATION 1. Collect the cable (fine multi strand copper conductor). 2. Collect the spade connector suitable to the wire thickness and terminal size (6mm diameter) 3. Select the wire stripper blade size to match the wire thickness (auto-eject) or adjust the jaws of the stripper. 4. Strip off a length of insulation that suits the terminal size (spade connector). 5. Twist the strands of the wire lightly in the direction of strands. 6. Select the crimping pliers that match with the terminal size. 7. Clamp the spade connector with the crimping pliers 8. Insert the wire far enough in the compression connector. 9. Apply light pressure to create a light impression on the compression connector. 10. Check whether the press is located in the middle of the band of compression connector and if necessary, make final adjustment. 11. Apply sufficient pressure in the handle to press the compression connector fully. 12. Check whether the prepared compression/crimping joint are firm by pulling the cable and compression connector. 13. Repeat the crimping of compression in connectors various sizes of copper and aluminum conductors of different lengths. SAFETY PRECAUTIONS  Be sure not to cut or damage the wire core  Don not clamp the insulation in the terminal  Strands must not stick out of the connector  Don not strip off too much insulation
56 NAME OF THE EXPERIMENT Identify the phase and neutral in single phase AC supply LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Test and identify a phase wire and neutral with the help of a test lamp  Test and identify a phase wire and neutral with the help of a voltmeter  Test and identify a phase wire and neutral with the help of a neon tester  Identify phase and neutral with the help of colour coding CIRCUIT DIAGRAM MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 Test lamp 230V / 250V 40W/60W/100W 1 each 2 Volt Meter 0-300V MI 1 no. 3 Neon Tester 500V 1 no. 4 Connecting leads 2mtr PROCEDURE AND OBSERVATION Task 1: Test lamp method 1. Connect the test lamp 230V/250V, 40/60/100W with supply for checking its function 2. Connect one lead of the test lamp to the earth point 3. Touch the other lead of the test lamp to any one of the supply terminals
57 4. Does the test lamp glow? If yes, mark the terminal as PHASE. Go to step 7 5. If the test lamp does not glow, touch the lead to the other supply terminal. Observe the lamp condition. 6. Mark this terminal as PHASE (L), if the lamp glows. 7. Remove the lead connected to earth. Touch both leads of the test lamp across the supply terminals. 8. Mark the unmarked terminal as neutral (N), if the lamp is glowing. Task 2: Voltmeter method 1. Connect the voltmeter (300V, MI) across the supply mains and check for indication of the supply voltage. 2. Connect one lead of the voltmeter to the EARTH POINT. 3. Connect a testing prod to the other terminal of the voltmeter. 4. Open the cover of the isolating switch fuse unit (ICDP) and touch with the other lead of the voltmeter to any one of the supply terminals 5. Observe the voltmeter; if it reads the supply volt, mark the terminal with the testing lead. Observe voltmeter reading. 6. If The Voltmeter is not indicating /reading, touch the other supply terminal with the testing lead. Observe voltmeter reading. 7. Is the voltmeter indicating the supply voltage? If yes, record the value ______ volts. Mark this terminal of supply as PHASE. 8. Remove the lead connected to earth and touch the other supply terminal with it. 9. If the meter reads the supply voltage, mark the unmarked supply terminal as Neutral. Task 3: Neon Tester 1. Check the neon tester for its function. 2. Place the testing end of the neon tester in any one of the socket outlet terminals 3. Touch the other end of the neon tester with your finger. If the neon tester glows that terminal is PHASE. 4. If the neon tester is not glowing, remove the neon tester and touch the other terminal. Observe the neon tester‟s glow condition. 5. If the neon tester is now glowing, mark the terminal as PHASE. SAFETY PRECAUTIONS  If the voltmeter is not reading when touch with either of the terminals and earth, check for AC supply failure  Make sure you are touching the wall or floor well with hand /foot for bright indication of the neon tester  The phase should be connected to the left side terminal of ICDP. The right side terminal is always neutral. (this is the recommended code of practice)
58 NAME OF THE EXPERIMENT Identify, dismantle, sketch and assemble different electrical accessories LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Identify specified electrical accessories of the following categories used in domestic wiring  Switches  Lamp –holders  Socket outlets  Ceiling roses  Fuse units  Fan regulators  Dismantle the above accessories to identify the holes for mounting, cable entry and connecting terminals  Assemble the accessories  Represent the accessories by standard symbols CIRCUIT DIAGRAM Socket 3pin Single pole switch Fuse cut out Plug top 3pin
59 Ceiling Rose Pendent holder Fan regulator Batten holder MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 Single pole switch 6A, 250V 2 nos. Yes 2 Socket (3 pin) 6A, 250V 2 nos. Yes 3 Plug top(3pin) 6A, 250V 2 nos. 4 Fuse cut out 6A, 250V 2 nos. 5 Ceiling rose 6A, 250V 2 nos. 6 Pendent holder 6A, 250V 2 nos. 7 Fan regulator 6A, 250V 2 nos. yes 8 Batten holder 6A, 250V 2 nos. 9 Socket – 3pin 16A, 250V 2 nos. Yes 10 Plug top -3pin 16A, 250V 2 nos. yes 11 ICDP switch 16A, 250V 2 nos. 12 DP switch 16A, 250V 2 nos. yes 13 Bell push 6A, 250V 2 nos. 14 Single pole MCB 10A, 250V 2 nos. yes 15 Double pole MCB 16A, 250V 2 nos. yes 16 Three pole MCB 32A, 440V 2 nos. yes 17 Four pole MCB 63A, 440V 2 nos. yes 18 ELCB 32A, 440V 2 nos. yes 19 RLCB 63A, 440V 2 nos. yes 20 Two way switches 6A, 440V 2 nos. yes TOOLS REQUIRED  Screwdriver 150mm with 4mm blade width - 1 no.  Connector screwdriver 100mm - 1 no.  Tray 10x10x4 cm - 1 no.  I.S. books on graphic symbols - 1 set (B.I.S 2032 all parts)
60 PROCEDURE AND OBSERVATIONS 1. Identify each accessory and write the name in the attached sheets. 2. Write the specification of each accessory by the side. 3. Dismantle the accessory carefully. 4. Compare the actual internal parts of the given accessory with the internal view of each accessory given in the sheets for identification. 5. Fill up the answers in the identification column given against each accessory. 6. Assemble the accessory. 7. Identify the symbols used for the accessory from the related theory or B.I.S books and sketch the symbols in the columns / spaces provided. 8. Show the completed sheets of specifications, identification and symbols to the instructor and get his approval. SAFETY PRECAUTIONS  Most of the specifications can be collected from the markings on the accessory itself. Otherwise try to get them from an approved catalogue or approach the instructor for guidance.  Open only one accessory at a time. Take care of the fixing screws, rings and washers.  Collect the parts in the tray. Metal parts inside the accessory need not be removed.  Different manufacturers design the outline of accessories differently to suit various conditions. However, the electrical contact positions of the accessories remain the same. As such there should not be much difficulty in identifying the accessories.  On the other hand, single way and two way switches as well as two and three plate ceiling roses look alike. A careful look at the rear of the accessory will make the identification process much easier.
61 NAME OF THE EXPERIMENT Study of Multimeter LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Measure AC/DC voltage  Measure current  Continuity test  Measure resistance CIRCUIT DIAGRAM MATERIAL REQUIRED  Multimeter (1000V for AC and 650V for DC) - 1 each  Torque tester (600A) - 1 no. TOOLS REQUIRED  Cutting pliers - 1 no.  Neon tester - 1 no.  Screwdriver set - 1 no. PROCEDURE AND OBSERVATION Task 1: Measuring AC voltage 1. Take multimeter/clip-on-meter and set the switch to AC position 2. Plug the two leads of the meter to 3. Measure the voltage between phase & neutral, phase & earth and neutral & earth. (if any leakage) Task 2: Continuity Test 1. Set the multimeter switch to position 2. Plug the leads if the meter to
62 3. Check for continuity of a wire, bulb, choke etc. It gives beep sound in case of continuity. 4. Set the meter switch to position 5. Follow step 2 6. Meter shows the resistance of the particular things Task 3: Measuring current 1. Unplug the leads of the meter 2. Set the switch to position 3. Hook the clips/ jaws of the meter to any live wire 4. Meter shows the flow of current SAFETY PRECAUTION 1. Set the meter position and range properly. 2. Do not measure beyond the rated voltage, current etc. 3. Hold / touch the leads properly.
63 NAME OF THE EXPERIMENT Makin of test board (series and parallel) LEARNING OBJECTIVES  To check the continuity  To check the loupe etc CIRCUIT DIAGRAM Fig. 1: Series circuit Fig. 2: Parallel circuit MATERIALS REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 SP switch 230V / 6 Amps 2 nos. Yes 2 2-pin socket 230V / 6 Amps 1 no. Yes 3 Batten Holder 2 nos. 4 Pin plug Top 230V / 6 Amps 1 no. 5 Wire wire 1.5 sq.mm Single conductor 5 mtr 3 mtr 6 Wooden box 12” x8” 1 no.
64 TOOLS REQUIRED  Screwdriver set - 1 no.  Cutting pliers - 1 no.  Neon tester - 1 no.  Electrician knife - 1 no.  Wire stripper - 1 no. PROCEDURE AND OBSERVATIONS 1. Fix the switch, socket and holder in a line on the cover of the wood board. 2. Do the wiring as per the circuit diagram. 3. For parallel circuit board, fix the switch & holder in line. 4. Connect the wires as shown in circuit diagram. 5. Fix / connect 2 single conductor wires as testing leads to 2 pin plug top. 6. To check any continuity plug the 2 pin plug (testing leads) and hold the other bare ends properly. 7. Switch ON the power supply 8. For testing purpose short the 2 ends of testing leads 9. Now you can check any continuity of motors, choke, wire etc. SAFETY PRECAUTION 1. Connect the phase wire through switch only. 2. After continuity check, switch off power supply & unplug the leads. 3. Be careful when you are testing the components.
65 NAME OF THE EXPERIMENT Assemble and install a fluorescent lamp LEARNING OBJECTIVES At the end of this exercise, the aspirant will be able to  Form a circuit for fluorescent lamps of a given size for domestic purposes.  Connect a fluorescent lamp with accessories and install it. CIRCUIT DIAGRAM MATERIALS REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 Tube light fitting set 1200mm 1 2 Starter choke 230V 40W 1 each 3 Fluorescent lamp 1200mm/40W/230V 1 no. 4 Flexible wire Twin twisted 14/.02 copper 4 mtr TOOLS REQUIRED  Test lamp 40W, 240V - 1 no.  Nose pliers 150mm - 1 no.  Connector screwdriver 100mm - 1 no.  Electrician‟s knife - 1 no.  Cutting pliers 150mm - 1 no.
66 PROCEDURE AND OBSERVATION 1. Check the choke for its short and open with a test lamp as shown in fig and record the results. 2. Check the starter with a series test lamp as shown in Fig. Observe the flickering of the lamp which indicates good condition of the starter. 3. Assemble the following fluorescent tube accessories in the fitting base. Refer to the sketch. 4. Connect the accessories as shown in Fig. and install the tested starter. 5. Test the filament on both sides of the fluorescent tube for its continuity as shown. Discard the fluorescent tube with open or fused filament in either side. 6. Fix the bulb in the holder  Firstly, you have to make sure that the slot in the inner parts of the holder is turned to the proper position.  Then insert both the ends (pins) into the holder of the fittings on either side of the tube. Push the socket pins all the way into the fittings until you feel that you can turn the tube in the sockets. 7. Test the tube light assembly for its working. SAFETY PRECAUTIONS  Be careful not to bend the pins at either end of the tube.  Check the supply at the ceiling rose. Switch off the supply before making any connection.
67 NAME OF THE EXPERIMENT Assemble, connect and install a twin fluorescent lamp with accessories LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Form the circuit for a fluorescent lamp of a given size for domestic and industrial purposes  Connect a fluorescent lamp with accessories and install  Connect a twin-tube fluorescent lamp with accessories, capacitor in series with one tube CIRCUIT DIAGRAM MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 Twin Tube light fitting set 1200mm / 220V /40W 1 set 2 Fluorescent lamp 40W / 230V 2 nos. 3 Starter 40W / 230V 2 nos. 4 Capacitor 3.15 MFD /380V 2 nos. TOOLS REQUIRED  Test lamp 60W with lead - 1 no.  Cutting pliers 150mm - 1 no.  Connector screwdriver 100mm - 1 no.  Screwdriver 150mm - 1 no.
68 PROCEDURE AND OBSERVATION (PARALLEL CONNECTION) 1. Check the choke for its short and open with a test lamp as shown in fig and record the results. 2. Check the starter with a series test lamp as shown in Fig. Observe the flickering of the lamp which indicates good condition of the starter. 3. Connect the accessories a per the circuit diagram for the 1200mm tube lights 4. Fix the starters and fluorescent lamps, connect the fitting to the supply and test. SAFETY PRECAUTION  Terminate the leads to a connector for connecting to the supply
69 NAME OF THE EXPERIMENT One Light control by switch LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Connect a lamp controlling through single pole switch CIRCUIT DIAGRAM MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 S P Switch 230V / 6A 1 no. 2 Switch holder 1 no. 3 Wires PVC pipes 2.5 sq.mm ¾ inch as reqd. as reqd. 4 Saddles Screws ¾ inch ¾ inch as reqd. as reqd. TOOLS REQUIRED  Screwdriver set - 1 no.  Cutting pliers - 1 no.  Neon tester - 1 no.  Electrician knife - 1 no.  Wire stripper - 1 no. PROCEDURE AND OBSERVATION 1. Fix the switch, batten holder at particular places. 2. Fix the pipes with saddles connecting holders and switch. 3. Draw the wires through the pipes and connect them according to circuit diagram. 4. Switch ON SAFETY PRECAUTION  Care should be taken while using tools.  Connect phase wire through switch only.  Connections should be tight.
70 NAME OF THE EXPERIMENT 3-pin socket control by switch LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Connect a 3-pin socket controlling by a switch CIRCUIT DIAGRAM MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical products required 1 S P Switch 220V / 6A 1 no. yes 2 3-pin socket 220V /6A 1 no. yes 3 PVC pipes ¾ inch as reqd. 4 Wire, Screws as reqd. PROCEDURE AND OBSERVATION 5. Fix the switch, batten holder at particular places. 6. Fix the pipes with saddles connecting holders and switch. 7. Draw the wires through the pipes and connect them according to circuit diagram. 8. Switch ON SAFETY PRECAUTION  Care should be taken while using tools.  Connect phase wire through switch only.  Connections should be tight.
71 NAME OF THE EXPERIMENT Complete wiring of a room LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Fix electrical circuit in the room. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Energy Meter --- --- --- 1 Nos. --- --- --- S.P. MCB 10 Amps. 1 Nos. Yes S.P. Switch 06 Amps. 1 Nos. Yes 3 Pin Socket --- --- --- 1 Nos. Yes Fuse, Lamp, Batten Holder --- --- --- 1 + 1 Nos. --- --- --- P.V.C Pipes and Wires, Screw Shaddle As Per Required --- --- --- --- --- --- TOOLS REQUIRED: 01. Cutting Plier 02. Nose Plier 03. Electrician Knife 04. Wire Stripper 05. Pocker 06. Screw Driver Set 07. Hammer 08. Flat Screw Driver 09. Neon Tester PROCEDURE AND OBSERVATIONS 01. Keep ready all tools / materials. 02. Fix the energy meter MCB & Fuse on a wood board.
72 03. Fix the switches & socket on another board. 04. Now fix the pipes connecting all accessories in a systematic manner. 05. Draw & connect all as per the circuit. 06. Ensure all are working properly & try to note the energy meter readings. SAFETY PRECAUTIONS 01. Connect energy meter connecting properly. 02. Fuse & MCB should be through phase wire any. 03. Do not short in socket, holder etc. 04. Connections should be tight.
73 NAME OF THE EXPERIMENT 2 Light Control by 2 Switches LEARNING OBJECTIVES: 01. Parallel connection of 2 lights. 02. Lights controlled individually. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Switch 220 V 16 Amps. 2 Nos. Yes Battern Holder with Lamps --- --- --- 2 Nos. Yes 1 P.V.C Pipes As Per Required --- --- --- --- --- --- Wires As Per Required --- --- --- --- --- --- Saddles/ Screws As Per Required --- --- --- --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Wire Stripper 03. Screw Driver Set 04. Neon Tester 05. Electrician Knife PROCEDURE AND OBSERVATIONS 01. Fix the switches, batten holders at proper places. 02. Fix the PVC pipes with saddles so that it connects holders & switches. 03. Draw and connect the wires through the pipes as per the circuit diagram. 04. Ensure the proper lumination of the experiment done. SAFETY PRECAUTIONS 01. Ensure the connections before giving supply. 02. Never connect neutral switches 03. Do not use broken accessories.
74 NAME OF THE EXPERIMENT Prepare a pipe earth and measure the earth electrode resistance LEARNING OBJECTIVES Objectives: At the end of this exercise you shall be able to  Dig an earth pit  Prepare a pipe earth according to B.I.S. specification.  Measure the resistance of the earth electrode  CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED G.I. pipe 12.7 mm dia. 5 m. --- --- --- G.I. bend 12.7 mm dia. 2 Nos. --- --- --- C.I. cover hinged to C.I. frame 300 mm square 1 No. --- --- --- G.I pipe 19 mm dia. 1 m. --- --- --- G.I. pipe 38 mm dia. having 12 mm dia. holes 2.5 m --- --- --- Reducer 38 x 19 mm 1 No. --- --- --- Funnel with 19 mm dia. sleeve 1 No. --- --- ---
75 & wire mesh G.I. nut for 19 mm dia. sleeve & wire mesh 1 No. --- --- --- G.I. check – nuts for G.I pipe 19 mm dia. 4 Nos. --- --- --- G.I. washer 40 mm with 19 mm hole 1 No. --- --- --- G.I. wire No.8 SWG 10 m --- --- --- Copper lug 200 amps with 19 mm dia. hole 1 No. --- --- --- Solder 60 / 40 100 gms. --- --- --- Match box --- --- --- 1 No. --- --- --- Soldering paste --- --- --- 10 gms. --- --- --- Cement --- --- --- 10 Kgs. --- --- --- Blue metal chips 6 mm size 40 Kgs. --- --- --- River sand --- --- --- 80 Kgs. --- --- --- Salt (common) --- --- --- 3 bags --- --- --- Coke or charcoal --- --- --- 3 bags --- --- --- TOOLS REQUIRED  G.I. die stock with 12.7 mm, 19 mm and 38 mm dies 1 set  D.E spanners 5 mm to 20 mm 1 set of eight  Blow lamp, 1 litre with kerosene 1 No.  Crowbar, hexagonal 1800 mm long 1 No.  Powrah (spade) 1 No  Cement mortar tray 2 Nos.  Tongs 300 mm 1 No.  Measuring tape 5 m 1 No.  Ladle 2 Nos.  Combination pliers 200 mm 1 No.  Pipe wrench 50 mm 1 No.  Hacksaw with 32 T.P.I blade 1 No.  Wooden box 150 (l) x 150 (b) x 300 (h) mm 1 No.  Soldering pot (melting) 1 No. EQUIPMENT / MACHINES  Earth tester with connecting leads and spikes 1 No. PROCEDURE AND OBSERVATIONS 01. Collect G.I. pipes and the accessories. 02. Make a slant cut of 30 in the 38 mm dia. G.I. pipe to have sharp edge as shown in Fig. 1. 03. Make threads in the other end of 30 mm dia. G.I. pipe to a length of 25 mm. 04. Make threads in both ends of 19 mm dia. G.I. pipes to a length of 25 mm on one side and 75 mm on the other side. 05. Fabricate the 38 mm and 19 mm dia. G.I. pipes as shown in Fig. 1 06. Select an earth pit site at least 1.5 meters away from the building foundation. 07. Dig an earth pit of dimensions 1 m width x 1m breadth x 3.75 m depth. 08. Place the fabricated pipe in an upright position as shown in Fig. 1 and position the pipe with help of bamboo sticks. 09. Place the wooden box around the pipe and fill it to a height of about 15 cm with charcoal, and fill the surrounding outer space of the box with soil.
76 10. Lift and place the wooden box above the coke layer. Fill up with salt to a height of about 15 cm and to an area of 150 x 150 mm area around the pipe. 11. Repeat the above steps 10 and 11 up to 2.5 meters as shown in Fig. 1 12. Place the G.I. Pipe 12.7 mm dia. with G.I. bends in proper position for E.C.C connection. 13. Prepare the concrete mixture and build the structure as shown in Fig. 1. 14. Fix the G.I. cover also 15. Insert the G.I. wire No. 8 SWG through the 12.7 mm dia. G.I. pipe. 16. Use the ladle and the blowlamp and melt the solder. 17. Solder the lug in the G.I. wire. 18. Insert the lug in the 19 mm dia. G.I. pipe and tighten it with G.I. nut and check nut. 19. Pour three or four buckets of water through the funnel. 20. Test the earth electrode resistance with an earth megger. (The method of measuring earth resistance is given in Ex. 306. Follow the procedure. The earth continuity conductor (E.C.C.) should not be connected to the earth electrode resistance has been given earlier. Check the value. 21. Enter the value of the earth electrode resistance in column 5 of Table 1. Fill up the other particulars also. The acceptable value of the earth electrode resistance has been given earlier. Check the value. 22. If the earth resistance is found higher than the acceptable value, make one more pipe earth electrode at a distance of 8 meters from the earlier one and connect both of them in parallel. 23. Measure the earth electrode value and enter it in column 6 of Table 1. SAFETY PRECAUTIONS 01. An earth electrode should not be installed in proximity to a metal fence to avoid the possibility of the fence becoming negative. If the metal fence is unavoidable. It should be earthed. 02. The depth given here is the minimum recommended. However, the depth may be increases till moist soil is reached. 03. Allow an hour for the water to be absorbed in the earth. 04. The second reading with two electrodes will be approximately half the first reading will be approximately half the first reading which was taken with one electrode. The measured value should be within the recommended value. If not, you may have to go for another earth electrode at a distance of 8 meters from the other electrodes.
77 NAME OF THE EXPERIMENT Fixing of tube light fitting LEARNING OBJECTIVEs  At the end of this exercise you shall be able to  Form a circuit for fluorescent lamps of a given size for domestic purposes.  Connect a fluorescent lamp with accessories and install it. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Tube light fitting with all accessories --- --- --- 1 No. --- --- --- Wooden Guttar screws --- --- --- 2 Nos. 2 Nos. --- --- --- Adopter --- --- --- 1 No. --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Flat Screw Driver 03. Neon Tester 04. Screw Driver Set 05. Hammer 06. Drill Machine 07. Pocker 08. Wire Stripper PROCEDURE AND OBSERVATIONS 1. Check the choke for its short and open with a test lamp and record the results. 2. Check the starter with a series test lamp. Observe the flickering of the lamp which indicates good condition of the starter. 3. Assemble the following fluorescent tube accessories in the fitting base. Refer to the Sketch. 4. Connect the accessories as shown in Fig. Also install the tested meter.
78 5. Test the filament on both sides of the fluorescent tube for its continuity as shown in Fig. 5. Discard the fluorescent tube with open of fused filament in either side. 6. Fix the bulb in the holder.  Firstly, you have to make sure that the slot in the inner parts of the holder is turned to the proper position.  Then insert both the ends (pins) into the holder of the fittings on either side of the tube. One end is shown in Fig. 6 Push the socket pins all the way into the fittings until you feel that you can turn the tube in the sockets. SAFETY PRECAUTIONS 01. Be careful not to bend the pins at either end of the tube. 02. The fixing of the tube to the wall, ceiling or tubular post should be strong enough to support the weight of the fitting. 03. The installed fitting must be below the level of the ceiling fan to avoid the flickering effect of the shadow. 04. Check the supply at the ceiling rose. Switch off the supply at the ceiling rose. Switch off the supply before making any connection.
79 NAME OF THE EXPERIMENT Complete wiring of 1 bhk house LEARNING OBJECTIVES o Planning estimation & costing of wiring of 1 BHK house with all connections. o Learning more about switch & socket, fan connection etc. CIRCUIT DIAGRAM TOOLS REQUIRED 01. Cutting Plier 02. Nose Plier 03. Wire Stripper / Electrician Knife 04. Wire Cutter 05. Hammer 06. Drilling Machine 07. Chiesel 08. Junper 09. Cutting Machine 10. Screw Driver Set 11. Neon Tester 12. Screw Driver SAFETY PRECAUTIONS 01. Take care should be taken while using electrical accessories / tools. 02. Aware of injuries while hammering etc. 03. Connect only phase wire through switches. 04. Avoid loose connections / change broken accessories.
80 MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED S.P Switch 5 Amp / 230 V 09 Yes 3 Pin Socket 5 Amp / 230 V 03 Yes Batten Holder, Ceiling Rose 5 Amp / 230 V 04 02 --- --- --- M.C.B 10 AMP / 230 V 01 --- --- --- Fuse Cut out 10 AMP / 230 V 01 Yes Wire, PVC, Pipe, Saddles, Screws All as per reqd. --- --- --- Wood Board + Box All as per reqd. --- --- --- PROCEDURE AND OBSERVATIONS a. Mark the location of the control points, out led points cable run in the given lay out drawing of bed room. b. Tube light and fan control by a switch near the entrance. c. The cable routing of the room insulation has to be carried out only in either straight and horizontal and vertical cable run. d. Mark the position of the control point outlet points and cable run on the wall surface of the wall.
81 NAME OF THE EXPERIMENT Service, repair and install a ceiling fan LEARNING OBJECTIVES Objectives: At the end of this exercise the aspirant will be able to  Test the given ceiling fan for its working.  Dismantle the ceiling fan.  Trace and identify (or) locate faults in the ceiling fan.  Replace faulty parts with good / rectified ones.  Test the capacitors  Clean and lubricate the bearings  Test the motor winding for continuity  Check the speed regulator  Assemble the ceiling fan and test for its working. CIRCUIT DIAGRAM REQUIREMENTS Tools / Instruments 01. D.E spanner set (6mm to 22 mm) 1 No. 02. Screw driver 100 mm, 150 mm each 1 No. 03. Heavy duty screwdriver (300 mm x 8 mm) 1 No. 04. Megger 500 V 1 No. Equipments / Machines 01. Different makes of ceiling fans 3 Nos. Materials 01. Connecting leads as reqd. 02. Crease for bearing as reqd. 03. Insulation tape P.V.C. as reqd. 04. Test lamp 230 V 40 W 1 No.
82 Fig 1 Fig 2 Fig 3 Fig 4 Fig 5 Fig 6
83 PROCEDURE Task 1: Servicing 01. Switch “ON” the fan and check for its smooth functioning at different settings of the regulator. 02. Isolate the fan circuit from supply by  Removing the circuit cu – out or  Switching off the mains and removing the fuse units. 03. Conduct visual inspection  For good condition of switch  For proper mounting of regulator and firm fitting of knob. 04. Open the switch over. Remove any external deposits, using a hair brush. 05. Check firmness of termination. Open the regulator and clean the inside with a brush. Check and adjust the contract, terminations (Fig 1) 06. Measure the insulation resistance between the outgoing terminals of the regulator and earth. (Fig 2) Record its value in Table 1. 07. Make arrangements to reach to the ceiling fan through stable means of elevation. (Ladder, table etc. the safety of a person is of utmost importance. Fig 3) 08. Note down the visual marking made on the fan, if any, and the name plate details for filling up the entries in Table 1. 09. Remove the fan blades in succession and refit the screws and spring washers in their place, in the body of the fan. 10. Slide the top and bottom canopies for inspection and cleaning. (Fig 4) 11. Inspect the supporting hook, grommet, shackle, supporting system, split pin etc. 12. Inspect the cotter pin, check nut, connections to the capacitor, fan leads, connector (Fig 5). Clean the external dust, dirt with a brush. 13. Clean the fan body first with a dry cloth and then with a wet cloth. 14. On inspection after sliding the canopy, if any excess of moisture or water is found, bring the fan down with the rod for testing its insulation resistance. 15. Dry the fan body by external heating with 500 W or 1000 W bulb or in an oven. If insulation is weak due to dampness. 16. Clean the blades thoroughly and mount them back. Apply grease / oil the screws at the time of fixing the blade. 17. Test the fan for its smooth functioning, after resuming supply to the fan circuit. 18. Record your observations about the points listed in Table 2. TABLE 1 Name of appliance: Serial No. Voltage Sweep Make Supply Current Watts Special Marking Insulation resistance between terminal & body Megohms Date of servicing Recommended repair / replacement made, if any TABLE 2 Sl.No. Points to be observed Condition Normal Abnormal 01. Speed 02. Noise 03. Heat (after 10 min. run) 04. Wobbling 05. Function of regulator in all positions
84 Task 2: Repairing Listen to the user‟s complaints. Complaints may be  Fan is not running  Fan is noisy  Fan wobbles excessively  Motor runs hot. Fan is not running 01. If there is no incoming supply to the fan, check the concerned branch circuit fuse and ensure the availability of supply in the fan circuit. 02. Check for the supply in the outgoing lead from the regulator to the fan. If any fault is noticed in the switch and / or regulator, rectify it. 03. Ensure free rotation of the fan by rotating it manually. 04. Check the supply at the fan terminals (either at the fan terminals or at the ceiling rose.) 05. Give temporary connection for further testing, if there is no supply at the ceiling rose. 06. If even after step 5 is done, the fan is not running, check the connection of the capacitor for loose connection after switching off the supply. 07. Switch ON the supply. If the fan is not running, the cause may be a defective capacitor. 08. Replace the capacitor with an identical good capacitor. 09. If even after replacing the capacitor the fan is not running, lower the fan and send it for testing of winding, and for necessary repair. Fan is noisy: 01. Collect the history and nature of the noise of the fan from the user. 02. Run the fan and observe the noise. Identify whether the noise is due to one or a combination of the following (The parts are shown in Fig 6.) a. Slack canopy – touching the rotating body. b. Worm out / partly out shackle. c. Loose element of the blade. d. Loose or missing screws. e. Capacitor housing slack. f. Broken or worn out split pin at the top and bottom. g. Lack of lubrication, or dirt in bearing. h. Worn out bearing / bush. i. Blade distortion / breakage. j. Alignment of blades. Fan Wobbles excessively 01. Check to be sure that the screws which attach the fan blade flanges to the motor hub are tight. 02. Check to be sure that the fan blade flanges seat firmly and uniformly to the surface of the motor hub. If the flanges are seated incorrectly, loosen the flange screws and re tighten. 03. Tighten the hanger bracket screws to the junction box, secure the hook. 04. Interchange the adjacent (side by side) pair of blades. If the fan blades are out of balance, it can redistribute the weight and result in smoother operation. Motor runs hot. 01. Check for partial short circuit in winding. If defective, send it for rewinding. 02. Check for tight bearing, if it is defective, replace it with good bearing. Repeat the above steps for 3 different makes.
85 Task 3: Installation of fan 01. Cut selects the down rod length such that the blades remain at 2.4 to 2.7 m above the floor. Do not mix the blades of one set with another set as the blades are matched as a set. 02. Insert the connection wires and then slip in the canopies back to back through the down rod. 03. Insert the down rod on the spindle and tighten with the bolt and nut separately packed with the hanger clamp. (Fig 6) 04. Remove the bolt and nut from the hanger assembly. (Fig 7) 05. Insert the down rod top end in the hanger clamp assembly and tighten with bolt and nut. Providing spilt pin, cotter pin at both ends of the down rod in a fan is almost to prevent falling of the fan by slackening of the bolt / nut securing. 06. Connect the wires to the terminal block, as per the instructions of the manufacturer. 07. Refit the bolt, nut with rubber shackle in the hanger clamp assembly. 08. Suspend the fan (without blades) by a pipe or rod inserted through the shackle as shown in Fig 8. 09. Connect it to the rated supply for a short while and observe for smooth running in the proper direction. 10. Mount the fan in the ceiling hook / supporting hook. Ensure the split pin is inserted in the bolt and bent/or the lock nut is fitted. 11. Connect the wires to the ceiling rose. Slacken, slide and fix the canopies to voer the top hook and spindle terminals block and capacitor. Ensure that the canopies are fitted with just sufficient spacing. 12. Fox the blade with screws already provided on the motor.
86 NAME OF THE EXPERIMENT Fan controlled by regulator through switch LEARNING OBJECTIVES  How to connect a fan through regulator CIRCUIT DIAGRAM Fig 7 Fig 8 Fig 9 MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED P switch fan regulator 6 A – 250 V 1 No. Yes Ceiling rose, ceiling fan --- --- --- 1 No. 1 No. --- --- --- PVC pipes, saddles / screws --- --- --- 1 No. --- --- ---
87 Task 4: Installation of fan regulator Read the manufacturer‟s instructions and diagram of the regulator connection and follow the instructions. 01. Installation of a fan regulator of a particular type. 02. Loosen the screw (1) inside the knob with the help of a small screwdriver. (Fig 9) 03. Lift the knob (2) by a screwdriver. (Fig 9) 04. Remove top cover (4) by unscrewing the two screws (3) under the knob (Fig 9) 05. Take out the wires through the base plate and make a series electrical connection at the switch. 06. Fix the base plate to the wall. 07. Fix the top cover by the screws and insert the knob. 08. Tighten the knob by the grub screw (1). 09. Test the fan for its working by connecting to the supply. TOOLS REQUIRED: 01. Cutting Plier. 02. Neon Tester 03. Wire Stripper / Electrician Knife 04. Dousce End Spanner 05. Screw Driver Set PROCEDURE AND OBSERVATIONS: 01. Fix the switch & regulator at particular places. 02. Connect regulator in series with the switch. (Refer circuit diagram) 03. Check the fan is fitted perfectly. 04. Fist switch on the switch and then operate the regulator. 05. Check the fan is working or not. SAFETY PRECAUTIONS: 01. Never connect neutral wire to regulator / switch. 02. Fix the cover before giving supply. 03. Ensure the connections.
88 NAME OF THE EXPERIMENT Power sockets controlled by DP switches LEARNING OBJECTIVES  Knowing connection from D.P to power socket.  Phase wire and neutral wire controlled by switch.  Do not make short in socket. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Main Switch Double Pole Switch 25 – 32 Amp 230 V 16 Amp – 230 V 1 2 Lamp Water Heater 6 Amp – 230 V 230 V 1 1 Wire, wooden box, saddle, screws As per reqd. All items TOOLS REQUIRED 01. Cutting Pliers 02. Electrician Knife 03. Screw Driver, Flat & Philip 04. Neon Tester 05. As per required wire, and others SAFETY PRECAUTIONS 01. Do not make short circuits. 02. Phase and neutral controlled by switches. 03. Water heater must be fixed proper insulation otherwise, shock water leaking etc. PROCEDURE AND OBSERVATIONS: 01. Fix the DP switches side by side in wood box. 02. Draw 4 Sq.mm wire & 2.5 Sq. mm wire separately from the mains 03. Connect 2.5 / 4 Sq. mm wire 2 DP switches fix so that it connects lighting and heating circuits respectively.
89 NAME OF EXPERIMENT Complete wiring of 2 bhk house LEARNING OBJECTIVE 01. Planning and estimation and costing of a wiring of 2 BHK with all connection telephone, cable sockets, learn more of the switches and earth and energy meter must be fixed on proper place: Ex. 515 Pg. 299. CIRCUIT DIAGRAM: Follow the diagram of No. 1 BHK, MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Ceiling Fan --- --- --- 3 Nos. --- --- --- DP Switches 220 V / 5A 10 Nos. Yes Florescent Tube with hlder --- --- --- 4 Nos. --- --- --- Fuse, Socket 16 A – 230 V 7 Nos. Yes --- --- --- 3 Nos. --- --- --- PVC Wires and screws wall As per reqd. --- --- - -- --- --- --- As per reqd. --- --- - -- --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Electrician Knife 03. Ball Peen Hammer 04. Screw Driver, Flat & Philip 05. Neon Tester 06. Hand Drill with Drill Bits (all types) 07. Wire Cutter, Stripper 08. Long Nose Pliers. PROCEDURE AND OBSERVATIONS: 01. One light near the bed controlled by 2 switches. 02. One tub light controlled by a switch near the centre. 03. Wall sockets controlled by switches. 04. Mark the location of the entry and exit point of the supply in the bed room layout by study the building plan. SAFETY PRECAUTIONS 01. While the wiring is going on take care of connect for switches and power sockets. 02. Carefully working for drill and hammering. 03. Connection must be tight properly (not loose). 04. Earth must be proper fixing.
90 NAME OF THE EXPERIMENT 5 lights controlled by 5 switches LEARNING OBJECTIVE: Parallel connection of 5 lights. Lights controlled individually CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Lamp Holders --- --- --- 5 Nos. Yes DP Switch 230 V (6 A) 5 Nos. Yes Lamp --- --- --- 5 Nos. --- --- --- Screws and wires As per reqd. --- --- - -- --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Electrician Knife 03. Screw Driver, Flat & Philip 05. Neon Tester 06. Cutter for Wire, Stripper SAFETY PRECAUTIONS 01. Ensure the connections before giving supply. 02. Do the wiring through the bitted pipes & connect them as per the circuit. 03. Tapping of neutral / phase wire should be tight. 04. Check the wiring system with instructor and give the supply.
91 NAME OF THE EXPERIMENT Telephone and cable sockets LEARNING OBJECTIVE: Connection and socket knowing M / F sockets. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED T.V Cable Socket --- --- --- 01 --- --- --- Telephone Socket --- --- --- 01 --- --- --- Telephone Wire & Cable Wire --- --- --- As per Reqd. --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Electrician Knife 03. Wire Cutter & Stripper 05. Neon Tester or Screw Driver PROCEDURE AND OBSERVATIONS: 01. Fix proper terminal for cable socket. 02. After fixing cable check T.V picture. 03. Do soldering for the sockets. SAFETY PRECAUTIONS 01. T.V Cable and telephone line must be fixing the light properly. 02. Drawing these cables in separate pipes with an advantage and safe.
92 NAME OF THE EXPERIMENT Complete wiring of a 3 bhk LEARNING OBJECTIVE  Draw the plan of the rooms from house plan to a larger scale.  Locate the entry and exit points of the electric supply in the room.  Locate the position of electrical accessories according to requirement and prepare a layout diagram using B.I.S symbols and etc. PLAN CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Ceiling Fan DP Switch --- --- --- 5 A – 230 V 5 Nos. 15 Nos. --- --- --- Socket 230 V – 16 Amp 3 Nos. Yes Fluorescent Tube 40 Watt 5 Nos. --- --- --- Socket 230 V – 6 Amp 6 Nos. Yes Holders Wires As per reqd. 7 Nos. 7 Nos. --- --- --- Emergency socket Pump 16 Amp I.H.P (220 to 250 V) 3 Nos. 1 Nos. Yes PROCEDURE AND OBSERVATIONS a. Mark the location of the control points out let points and cable run the house. b. One light near the bed controlled from two places. c. One tube light controlled by a switch near the entrance. d. One fan at the center of the bedroom controlled by a switch and regulator near the entrance. e. The cable of routing of the room installation has to be carried out only in either straight and horizontal and vertical cable run. TOOLS REQUIRED 1. Cutting Pliers Wire Cutter & Stripper 2. Nose Pliers Drill Machine 3. Screw Driver Flat + Phillip Electrician Knife 4. Hammer + Drill Ladder + Steal measuring tape 5 mt. SAFETY PRECAUTIONS 1. Fixing the electrical accessories carefully handling. 2. Fixing the switches and socket not to be over eight. 3. Don‟t leave anything in the circuit board. 4. Carefully hammering and drilling.
93 NAME OF THE EXPERIMENT Hotel and Mini lodge of 6 rooms LEARNING OBJECTIVE  Plan of wiring and estimation and costing and making connections as per diagram of 6 rooms.  Decide how to route the connecting cable and main cable in the bedrooms taking into consideration aesthetic economic and labour aspects in the layout.  Mark the location of the entry and exit points of the supply in the bed room. CIRCUIT DIAGRAM TOOLS REQUIRED o Cutting Plier o Wire Cutter & Stripper o Nose Pliers & Electrician Knife o Hammer +Drill Machine o Screw Driver Flat + Neon Tester + Test lamp MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Bell Push 220 V (6 Amps) 6 Nos. Lamp indicating --- --- --- 6 Nos. --- --- --- Holders --- --- --- 6 Nos. Calling Bell --- --- --- 1 Nos. PVC Pipe & Wire As per Reqd. --- --- - -- --- --- ---
94 PROCEDURE AND OBSERVATIONS: 1. Fix the all lights at one place on to bell (also mark them) different places. 2. Now fix the PVC pipes so that it connects switches and lamp holders. 3. Draw the wires as required inside the pipe and do the wiring / connect the bell pushes and lamp holders as per circuit diagram. 4. Do the wiring neatly. 5. Test the system for proper working. 6. Connect only phase wire to the switch control. SAFETY PRECAUTIONS Carefully work of the Electrical items + Connect only phase wire to the switch control
95 NAME OF THE EXPERIMENT Wiring Of Corridor Lighting LEARNING OBJECTIVE 01. The corridor has a number of lamps 02. Each lamp has a controlled by a 2 switches. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Lamps & Holders --- --- --- 4 Nos. 4 Nos. --- --- --- Switches (Two Way) 220 V (6 Amp) 4 Nos. Yes P.V.C Wires As per required --- --- - -- --- --- --- PROCEDURE AND OBSERVATIONS 01. Each lamp are L1, L2, L3 and L4 are different lamps having controls at S1, S1, S2, S2, S3, S3, and S4, S4 respectively. TOOLS REQUIRED 01. Cutting Pliers 02. Nose Pliers and Electrical Knife 03. Wire Cutter and Stripper 04. Hammer, Screw Driver Flat and Philip 05. Neon Tester and Test Lamp SAFETY PRECAUTIONS 01. In two way switches operate the switching knob of the pairs alternatively to check the polarity 02. Properly fix the phase control to the switch.
96 NAME OF THE EXPERIMENT Identify 3 phases (4 wires) and know about the D.O.L Starter LEARNING OBJECTIVE Objective: At the end of this exercise you shall be able to a. Identify and collect the parts of a D.O.L starter. b. Assemble the D.O.L starter when contactor overload relay, push button stations and single strand cables are given in semi – knocked out condition. c. Connect and harness the hook – up cable for control circuit. d. Mount the D.O.L starter, the main ICTP switch and connect the 3 Phase induction motor e. Earth the motor, the starter and the switch f. Set the overload relay ® g. Replace correct capacity back up fuses. h. Start and stop the 3 – Phase induction motor through D.O.L starter. i. Measure the starting and the running currents of the 3 – Phase squirrel cage motor. j. Determine synchronous speed, slip and percentage slip. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED 3 Phase motor DOL starter 5 HP 10 A – 415 V with OLR 1 1 --- --- --- Single strand copper wire 165 WG 0.5 m --- --- --- Single strand wire 185 WG 0.5 m --- --- --- CTP Switch 16 A – 415 U 01 --- --- ---
97 TOOLS REQUIRED a. Combination pliers 200 mm b. Screw driver 300 mm with 4 mm blade c. Connector screw driver 100 mm d. Side cutting pliers 200 mm e. Electrician Knife f. Ammeter MI 0 – 20 amp g. Voltmeter MI 500 V h. Plumb bob with thread i. Spirit level j. Tachometer 0 – 3000 rpm PROCEDURE AND OBSERVATIONS 1. Note down the name plate details of the given AC 3 phase squirrel cage induction motor in Table 1. 2. Collect the contactor unit. Overloads relay unit, start / stop push button unit, the necessary fixing screws, hook up cables, I.C.T.P switch and D.O.L starter base and cover. 3. List the items you received from your instructor in Table 4. Record the name plate details of the contactor and overload relay in your record respectively. 5. Investigate and check the contactor input and output terminals, auxiliary and main terminals, movable and fixed contacts, no – volt coil, overload relay, their rating normally closed relay contacts and their operation. 6. Identify the connecting terminals for interconnecting no – volt coil, main supply to control circuit, normally open auxiliary contracts. 7. Identify the mounting screw holes in the contactor, overload relay and the corresponding holes in the starter base box. 8. Draw the complete circuit diagram for the given D.O.L starter with overload relay, no – volt coil, „ON‟ and „OFF‟ push buttons. 9. Get the diagram approved by the instructor. 10. Mount the accessories in the starter base box with the help of mounting screws. 11. Identify the place of connection of the hook up cables with the help of the approved diagram. Measure and cut the hook up cables leaving allowance for harnessing. 12. Connect the hook up cables according to the approved diagram. 13. Harness the hook up cables such that the cables do not interfere with any moving mechanism of the starter. 14. Check up once again the complete connection of the D.O.L starter internal wiring. 15. Get the wiring approved by your instructor. 16. Identify the holes in the starter base box for mounting the starter on the wall / frame. 17. Mount the starter vertically on the wall / frame. 18. Connect the main supply to the starter incoming terminals through the I.C.T.P switch. 19. Connect the starter outgoing terminals to the 3 phase squirrel caged induction motor along with the ammeter and voltmeter. 20. Connect the protective earthing continuity conductors to the main earth. 21. Investigate the full load current of the motor and set the overload relay of the starter to that rating. 22. Provide a back up fuse as recommended by the manufacturer of the starter considering the horse power rating of the motor. 23. Get the main connections, earth connections, overload setting and the backup fuse rating approved by your instructor. 24. Switch on the ICTP.
98 25. Start the motor by the start (S) button of the starter. 26. Read the ammeter for the starting current at the time of starting. 27. Read the voltmeter and ammeter values when the motor shows normal running. 28. Measure the actual speed of the rotor with the help of a tachometer. 29. Switch OFF the motor using stop (S2) button of the starter. 30. Switch OFF the mains, remove the fuses and disconnect the connections. 31. Determine the synchronous speed and enter the value in Table. 32. Show the readings to your instructor. SAFETY PRECAUTIONS 1. Do not tighten the screws more than necessary as too much tightening of screws will break the PVC casing of the contactor and OL relay. 2. The position of the starter should be such that the no – volt coil mechanism works properly, taking advantage of the gravitational pull while disengaging. 3. Before connecting the 3 phase squirrel cage motor, test it for continuity and insulation. 4. Preferably check for the backup fuse rating in the pamphlet supplied along with your starter.
99 NAME OF THE EXPERIMENT Manual Star – Delta Starter LEARNING OBJECTIVES At the end of this exercise you shall be able to identify the parts of a manual star – delta and trace the connection. 1. Draw the star / delta connection of motor winding through starter – handle operation. 2. Provide proper back up fuse in the main switch of the 3 phase squirrel cage motor according to the motor rating. 3. Connect the manual star – delta starter with 3 – phase squirrel cage induction motor. 4. Adjust the overload relay according to the motor current rating. 5. Start the 3 – Phase squirrel cage induction motor through the manual star – delta starter. 6. Stop the 3 phase squirrel cage induction motor through the manual star – delta starter. 7. Reverse the direction of rotation of the squirrel cage motor. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED PH Motor Star + Delta starter 10 HP – 10 – 15 amps, 415.V. 3 PH 01 C. insulated stranded 2.5 sq mm - 650 V 25 DP Switch 16 A – 415 V / 3P 01 Schneider Material As per required TOOLS REQUIRED 1. Insulated cutting pliers 200 mm 1 No. 2. Screw driver 200 mm, 300 mm 1 No. each 3. Side cutter 150 mm 1 No.
100 4. Wire stripper 1 No. 5. M.I ammeter 10 amp 1 No. 6. M.I Voltmeter 0 – 500 V 1 No. PROCEDURE AND OBSERVATIONS 1. Read and interpret the name – plate details of the given 3 – phase induction motor and starter and enter in Tables 1 (as per Exercise 1004) & 2. 2. Switch „off‟ the mains, remove the fuse – carriers and keep them in safe custody. 3. Remove the terminal cover of the motor and the front cover of the starter. 4. Indentify the parts of the given star – delta starter, trace the connections and study its operation. Draw the traced out circuit and get it approved by the instructor, 5. Draw the complete connection diagram incorporating the ICTP switch the given star – delta starter and motor and get it approved by your instructor. 6. Make the connections of the motor, starter and the ICTP switch as per the approved diagram. 7. Connect three cables from supply L1, L2 & L3 to the main. 8. Insert the ammeter in series with one of the line cables from the main switch and a voltmeter across two line cables. 9. Swire proper fuse element according to the given motor rating in the fuse carrier and insert the carriers and insert the carriers in the main switch. 10. Set the overload relay according to the full load current rating of the motor. 11. Provide double earth to the metal body of the main switch, starter and the motor frame. 12. Switch on the main, observe the voltmeter reading and move the handle to the star position positively and at the same time observe the starting current and enter it in Table. 13. Allow the motor to start, race initially and let the sound of the rotating shaft come to a steady state; then move the handle to the deita position positively. 14. Note down the direction of rotation and enter it in Table. 15. Note down the current taken by the motor in running condition and enter the value of the current in Table 3. 16. Then stop the motor by pressing the stop – button of the starter. 17. Switch „OFF‟ the main switch and remove the fuses. 18. Interchange the two line cables R‟ and Y‟ to terminals L2 and L1 respectively as shown in Fig 19. Insert the fuse carries in the main switch. 20. Repeat steps No. 12 to 15 and record the information in Tables. 21. Stop the motor, switch off the supply and remove the fuse; then interchange the line cables Y‟ and B‟ terminals L3 and L1 respectively as shown in Fig. 22. Insert the fuse carries in the main switch. 23. Repeat steps Nos. 13 to 16 and record the information in Tables. 24. Stop the motor and write your observations about the method of changing the direction of rotation. 25. Switch „off‟ the mains, remove the fuse – carriers and remove all connections. SAFETY PRECAUTIONS 1. To connect a star – delta, the squirrel cage induction motor must have six terminals, which are normally marked as U1, V1, W1 & U2, V2, W2. 2. Assumption: Check the connections for correctness and tightness. Get it approved by the instructor.
101 NAME OF THE EXPERIMENT Replace the heating element in a non-automatic electric iron and test LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Measure insulation resistance between the terminals and the body of the electric iron (R)  Test the given electric iron for its working (R)  Test the line cord for continuity (R)  Dismantle an electric iron  Trace and identify or locate faults in an electric iron  Replace a faulty heating element with a good one  Assemble the electric iron and test for its working CIRCUIT DIAGRAM Fig 1 Fig 2 TOOLS REQUIRED  Test lamp 100 W - 1 No.  Screwdriver 150 mm - 1 No.  Spanner D.E. 6mm to 22mm - 1 set  Megger 500V - 1 No.
102 EQUIPMENT/MACHINES  Electric irons (of different makes) - 3 Nos. MATERIALS REQUIRED Nichrome heating elements for electric irons - 3 Nos. (One for each make of the iron suitable to the iron under test) PROCEDURE AND OBSERVATIONS 1. Record the name-plate details of the given iron. 2. Disconnect the power cord from the electric iron as shown in Fig 1. 3. Read the assemble diagram of the iron. Dismantle the parts. Follow the sequence recommended by the manufacturer. 4. Follow the sequence given below to remove the parts, in the absence of the manufacturer’s recommended sequence of diagram of assembly. Fig 2 5. Remove the asbestos sheet and clean the pressure plate. 6. Obtain a suitable heating element after checking shape, wattage and voltage. 7. Check the new element for its continuity using an ohmmeter/test lamp. 8. Replace with the new element. Assemble the input including connection of the element. 9. Measure the insulation resistance of the element of the iron between the body and the terminals before and after connecting the cord. 10. Test the electric iron with supply for its working. 11. Replace the heating element for two different makes following steps 1 to 10. SAFETY PRECAUTIONS Ensure that the extension from the element is insulated (with mica or asbestos) properly. It is recommended to remove the asbestos sheet and replace with a suitable new one.
103 NAME OF THE EXPERIMENT Repair and rectify faults in an automatic electric iron LEARNING OBJECTIVES At the end of this exercise the aspirant should be able to  Connect and test the given domestic appliance (automatic iron) for its working  Dismantle the automatic iron and reassemble it  Trace and identify (or) locate faults in an automatic iron  Replace the faulty parts with good ones CIRCUIT DIAGRAM Fig 1 Fig 3 Fig 2 Fig 4
104 TOOLS REQUIRED  Multi meter - 1 no.  Test lamp 60 W, 240 V - 1 no.  Screwdriver 150 mm - 1 no.  Spanner set 6 to 22 mm - 1 set  Megger 500 V - 1 no. EQUIPMENT/MACHINE  750 W, 250 V automatic electric iron - 1 no. MATERIALS REQUIRED  750 W, 250 V heating element - 1 no.  Thermostat control device - 1 no.  Insulating materials such as asbestos and mica sheets suitable for that iron - 1 no. PROCEDURE AND OBSERVATION 1. Conduct a visual examination of the power cord and plug. 2. Conduct preliminary tests o Cord, for continuity & insulation o Iron, earth fault o Iron, defective element circuit 3. Replace the cord if necessary. 4. Check for the insulation resistance between line terminal of the iron and the body of the iron (Fig 1) and record in Table 1. 5. Check for insulation resistance between the neutral connector and earth. 6. Connect the iron to the mains and check for its working. 7. Check the presence of dangerous voltage existing between the body and earth of the supply with a neon tester or voltmeter. In case of earth fault 8. Disconnect the iron from the supply, dismantle it. Visually inspect and test with a multi-meter/Megger for any contact of live wire with the body. o Insulation failure o Broken parts o Damaged thermostat/actuating leaf porcelain o Switch actuator 9. Rectify the fault by replacing the defective part (element, thermostat etc.). In case of open in element circuit 10. Remove the cover to check the thermostat, indicator bulb circuit and element o Connect the series test lamp to the element circuit shorting the contacts of the thermostat indicated by 1 in Fig 3. If the test lamp glows, the thermostat is defective. o Connect the terminals of the indicating bulb by a piece of insulating wire, shown by 2 in Fig 3. If the test lamp glows the trouble is in this section.
105 o Short the terminals of the element shown by 3 in Fig 3. If the lamp glows the element is open. Replace the element. Failure of temperature setting controller 11. Check the adjusting knob for proper fixing and actuation of shaft (Fig 4). 12. Open the contacts of the thermostat and inspect them visually. 13. Clean the pitted or burnt out contacts, if reusable. 14. Check for the actuating mechanism. (Heat the thermostat by a suitable external heating device.). 15. Assemble the iron and test for safe working. SAFETY PRECAUTIONS Always disconnect the iron from supply while testing with insulation tester/megger
106 NAME OF THE EXPERIMENT Service and repair a wet grinder LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Read and interpret data of a wet grinder (R)  Test the line cord for continuity (R)  Measure the insulation resistance between the terminals (R)  Trace, identify and locate faults in a wet grinder (R)  Replace faulty parts with good ones/rectified ones (R) CIRCUIT DIAGRAM Fig 2 Fig 1 Fig 3 TOOLS REQUIRED  Electrician’s tool kit - 1 no.  Test lamp 40W, 240 V - 1 no.  Spanner set of 8 nos. 6mm to 22 mm - 1 no.  Pulley puller 3 leg 200mm - 1 no. EQUIPMENT/MACHINES o Wet grinder (ordinary) (0.25 HP, 230V, 50Hz) - 1 no.
107 PROCEDURE AND OBSERVATIONS Task 1: Servicing of a grinder 1. Switch on the grinder and check for its functioning. 2. Isolate the grinder from the supply. 3. Open the inspection cover. Note down the name plate details in Table 1. 4. Conduct visual inspection: o For supply cord o For good condition of switches o For proper mounting of motor and drive alignment (Fig 1) 5. Conduct an insulation test of the motor and record in Table 2. If the insulation value is above 1 megohm, switch on the grinder and observe its function. 6. If the insulation resistance is less than 0.5 megohm, improve the insulation value by heating or varnishing, provided the motor is opened for varnishing. 7. Clean thoroughly the motor and the bearing of the grinder. 8. Lubricate the bearing as recommended by the manufacturer before assembly. 9. Assemble the motor and tighten the terminal screws, pulley screws, flywheel nuts, motor fixing bolts etc. (after adjusting belt tension) 10. Connect the motor to the supply and start the grinder. Observe the working of the motor and the grinder for smooth running. Task 2: Repairing of grinder Listen to the complaints of the customer/user complaints may be: 1. Grinder not working 2. Fails to start but runs in either direction, when started manually 3. Starts but heats rapidly 4. Reduction in speed – motor gets too hot 5. Grinder is noisy 6. Grinder gives shock Grinder not working  Check whether there is open connection in line. Rectify the fault if observed.  Check for any open circuit in motor winding (starting and running winding). Send it for repairs, if open circuited. Fig 2  Check tightness of the belt. Adjust the belt for proper tension as recommended by the manufacturer. Fig 1  Check whether it is due to tight bearings. Test by turning the shaft by hand. If lubrication does not help the bearing must be replaced.  Check the contact of the centrifugal switch. If the contact of the centrifugal switch is not closed, repair it or replace it. Fig 3  Check the capacitor. Replace it if it is defective. Starts but heats rapidly  Check the centrifugal switch. If it is not opening, rectify or replace. Reduction in speed – motor gets too hot  Check the winding for its short circuit and grounding (earthing).  Check the bearing to know whether it is sticky or to repair or replace, if found defective.
108 Grinder is noisy  Check for worn out bearings – replace the bearings and inspect the shaft for scoring.  Check the end play, add additional end of preventing washers, if the play is too much  Check the loose parts (that is loose hold-down bolts, loose fan, pulleys etc). Tighten them.  Check whether there is misalignment. Align the pulleys correctly. Fig 1  Check the belt. Replace if it is worn out. Fig 1  Check the shaft of the motor. Replace or send the motor for repair, if found bent. SAFETY PRECAUTIONS Grinder gives shock:  Open the inspection cover and check for any line contact with the metallic body. Also ensure earthing is proper  Rectify the accidental contact, if any and insulate item properly.
109 NAME OF THE EXPERIMENT Service and repair of Geyser LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Read and interpret data of a geyser  Test the line cord for continuity (R)  Measure the insulation resistance between the terminals and the body of the geyser(R)  Dismantle a geyser (R)  Trace, identify and locate faults in a geyser  Replace faulty parts with good ones  Assemble a geyser and test for its working  Test the thermostat for continuity CIRCUIT DIAGRAM Fig 1 TOOLS REQUIRED  Megger 500V - 1 no.  Test lamp 60W, 240V - 1 no.  Line tester - 1 no.  Spanner set (6 to 22mm) - 1 no.  Thermostat 0 – 150 0 C - 1 no.
110 EQUIPMENT/MACHINES  Geyser (1500 watts) 25 litres - 1 no. MATERIALS REQUIRED  Geyser heating element 1500W, 230V - 1 no.  Geyser thermostat - 1 no.  3-core flexible cord (48/0.2) with15A 3-pin plug - 1 no. PROCEDURE AND OBSERVATIONS Task 1: Servicing geysers 1. Record the details of the application in Table 1 2. Open the inspection cover for electrical terminals connection and thermostat installation in the geyser after removing the power plug. 3. Conduct a visual examination of the i) power cord ii) plug pin termination and iii) termination at appliance. 4. Check for proper tightness and good electrical contact at terminations. Replace the plug pin if found petted. 5. Conduct the insulation test on the cord – between the leads, lead and earth. Enter in Table 1. 6. Measure the insulation resistance between the element and the earth/body and the resistance should be 0.5 megohm. If it is less than 0.5 megohm, send the geyser for repair and rectification. 7. Connect the geyser to the supply and switch on the appliance, keeping the inspection/bottom cover of the electrical connections open. 8. Observe that the heating process is cut off by the actuation of the thermostat. The time depends on the capacity of the geyser and the thermostat setting. 9. Switch off the supply. Remove the plug. Measure insulation resistance value between the terminals and the body of the heater/the thermostat while it is hot and record the value in Table 1. 10. Replace the thermostat hot unit if the insulation value is less than one megohm. 11. Refit the inspection cover. It the insulation value is normal (i.e. above one megohm_ apply grease over the screws before fitting. Task 2: Repairing geysers Listen to the complaints of the customer/user and not them. Proceed as stated below for the specific nature of fault/complaint. Nature of fault: 1. No hot water: Check for the undermentioned causes in the given sequence. a) No power b) Defective thermostat c) Thermostat out of calibration d) Defective heater element i) No power 1. Check the fuse of the circuit; replace the fuse, if blown. 2. Check the availability of power at the socket outlet using a test lamp
111 3. Open the inspection cover and check the cord for its continuity. Replace the cord if necessary. ii) Defective thermostat 1. Check the thermostat for continuity between its terminals at different settings. Replace the defective thermostat with a good one. No continuity between the terminals indicates defectiveness. iii) Thermostat cut off calibration 1. Adjust the thermostat for a higher setting. If the thermostat is found to be good, switch ON supply. Observe the fuse. iv) Defective element 1. Check the element for its continuity and insulation value between the terminal and the body (sheathing of the element). 2. Replace the defective heating element with an identical good one. Switch on the supply and observe. 2. Water too hot: Check for the undermentioned causes a) Thermostat set too high b) Defective thermostat i. Check the setting of the thermostat and adjust it to a lower value. Switch on the geyser. Wait for the thermostat to cut off the supply of for about 20 minutes. Open the inlet. Collect the water at the outlet and measure the hot water temperature. ii. If the water temperature is much higher than the set value of the thermostat, replace the thermostat with a good one. If the temperature of the hot water is close to the range setting of thermostat it indicates a defective setting as the only cause. 3. Water not hot enough: check for the undermentioned causes a) Thermostat set too low b) Incorrect heater element c) Excessive lime in tank i. Check the thermostat setting and adjust it to a higher value. If the geyser produces hot water with the resetting, then the earlier setting was wrong. ii. Check and test the wattage of the heating element. If it shows a lower value, replace it with a higher wattage element. iii. Remove the heating element; inspect the element and the inner side of the copper vessel for deposit of excess lime coating. In case the heating element is of correct wattage and the thermostat is properly set, remove the lime coating. SAFETY AND PRECAUTIONS 1. Drain the water from the container of the geyser before removing the element. 2. Switch off the supply and remove the plug before opening the cover. 3. The geyser should be switched on only with water in the container. 4. Check and ensure that the switch is off before removing the power plug.
112 NAME OF THE EXERCISE Repair and service of a table fan LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Test the given table fan for its working  Dismantle the table fan  Trace and identify or locate faults in the table fan  Replace faulty parts with good ones  Test the capacitors  Clean and lubricate the bearings  Check the oscillation mechanism  Check the speed regulator  Reassemble the table fan and test for its working. CIRCUIT DIAGRAM Fig to be added TOOLS REQUIRED  D.E spanner set 6 to 22 mm - 1 no.  Cutting pliers 150mm - 1 no.  Screwdriver 150mm - 1 no.  Soldering iron 65W, 230V - 1 no. EQUIPMENT/MACHINES  Table fans (one each of three different sizes) - 3 nos. MATERIALS REQUIRED  Connecting cables - as reqd.  Grease - as reqd.  Three-in-one oil / SAE 30 - as reqd.  Solder resin – cored - as reqd.  Insulation tape - as reqd. PROCEDURE AND OBSERVATION Task 1: Servicing of a table fan 1. Switch ON the fan and check for its function, at different settings of the speed regulator and oscillation mechanism. Observe and record the condition. Disconnect the fan from the supply 2. Conduct visual inspection on the  Main cord insulation  Plug pin termination for tightness and goodness electrical contact. 3. Set right the defects, if any is noticed. 4. Remove the front guard and blade assembly and clean them. Fig 1 5. Place the fan in a lying position on a pad or cloth.
113 Take care that the guard is not damaged 6. Open the bottom cover and clean the dust and dirt with a brush. 7. Disconnect the main cord. 8. Conduct the insulation test on the main cord and record the values. Replace it if the value of insulation resistance is less than 1 megohm. 9. Measure the insulation resistance of the fan windings and record it. Replace it if the value is less than 1 megohm. 10. Clean the regulator contacts. Reconnect the main cord. (Fig 1) Refix the bottom cover and keep the fan in normal position. 11. Remove the oscillating gear assembly. Clean and lubricate with fresh grease. 12. Lubricate the bush bearings with SAE 30 oil. (Fig 1) Fix the oscillation gear box in position. 13. Refix the blade and guard assembly. Switch ON the fan for its working. Task 2: Repairing of a table fan Listen to the user’s complaints. The complaints may be any one or a combination of the following. a) Fan is not running b) Noisy c) Not oscillating d) Fan produces humming noise e) Bearings of the oscillating mechanism rattle f) Oscillating mechanism is noisy A. Fan is not running. 1. Check the socket outlet for the availability of supply 2. Remove the bottom inspection cover 3. Check the continuity of the power cord 4. Check the regulator switch assembly. (Fig 1) Rectify if any faulty is observed. 5. Ensure free rotation of the fan with your hand. Find the cause and rectify if it is too tight (bearing assembly, foreign body etc.) 6. Check the capacitor. Replace if defective. (Fig 1) rectify loose connections if any. 7. Check the winding for continuity and insulation. (Fig 2) Send it for rewinding, if necessary. B. Fan is noisy 1. Collect the history and nature if the noise of the fan from the user. 2. Run the fan and observe the noise. 3. Identify the noise and find out if the noise is due to one or the combination of the following. o Loose element of the blade o Loose or missing screws o Lack of lubrication or dirt in bearing o Worn our bush o Blade distortion/breakage (fig 3) o Alignment of blades o Loosely fitted gaurds
114 C. Fan not oscillating 1. Check the compression stud, worm gear and pinion. 2. Check the gear for broken teeth 3. Check for a bent rotor shaft 4. Check the gear pin for proper setting. If it is loose, either knurl the end slightly and press it into place or replace the complete gear assembly. D. Fan produces humming noise 1. Check the air gap for unevenness. If it is incorrect check the correct fitting of the end shields as per the markings. 2. Check armature for a bent shaft 3. Check for worn out or loose bearing fit. If bearings are defective, replace them. When replacing, clean the washers and rotor shaft should be lubricated with a light film of SAE-30 motor oil. E. Bearings of the oscillating mechanism rattle 1. Check for worn out bearings, particularly at the fan blade side. 2. Check the rotor for excessive wear 3. Check for proper grease. Clean out the gear case and replace with the grease recommended in the service manual. F. Oscillating mechanism is noisy 1. Excessive end play between the compression stud and the cover may be the cause of this noise. To prevent excessive end play, use spacers between the compression stud and worm gear.
115 NAME OF THE EXPERIMENT Servicing and repairing of food mixer LEARNING OBJECTIVES At the end of this exercise you shall be able to  Read the interpret the data of the given food mixer.  Indentify the area of problem in the food mixer by visual inspection and tests.  Dismantle the food mixer.  Trace, identify and locate faults in the food mixer.  Replace faulty parts with good ones.  Clean and lubricate the bearings.  Assemble the food mixer and test for its working. REQUIREMENTS 01. Screwdriver set of three 1 No. 02. Test lamp 100 W, 240 V 1 No. 03. D.E. spanner set of six 6 mm to 22 mm 1 set 04. Plastic spanner for opening the jar screw 1 No. 05. Box spanner set of 6 mm to 22 mm 1 Set 06. Multimeter 1 No. 07. Megger 500 V 1 No. 08. Philips screwdriver 4 mm blade dia. 1 No. Equipment/ Machines 01. Food mixer 240 V 50 Hz. 400 Watts 1 No. Materials 01. Grease / lubricating oil as reqd. 02. Kerosene as reqd. 03. Cleaning brush 1 No. 04. Sandpaper smooth as reqd. 05. Soldering lead, 40:60, soldering flux as reqd. 06. Service manual (if available) 1 No. PROCEDURE Task 1: Servicing of a mixer 01. Note down the name plate details in the maintenance card. (Table 1) 02. Enter the details of the complaint from the customer in the maintenance card. 03. Switch on the mixer and check for its functioning. 04. Isolate the mixer from the supply. 05. Open the bottom cover and conduct visual inspection for:  Damages in the supply cord and loose terminal connections  Good condition of switches.  Proper mounting of the motor. 06. Check whether the nylon / rubber coupling of the jar and motor are properly seated, if not replace. Sometimes the retaining spring and washer might have got spolled and need to be replaced.
116 TABLE 1 MAINTENANCE CARD 07. Remove the insulation value by heating or varnish if the insulation value is less than one megohm enter test results in the maintenance card. (Table 2) 08. The motor is opened for varnishing, clean thoroughly stator and armature and bush bearings. (Fig 2) 09. Conduct the insulation test after varnishing and enter results in the maintenance card (Table 2). Remember that the nuts at the blades and the centre shaft holding nut are to be loosened by clockwise movement and tightened by anti – clockwise movement in the most of the mixers. 10. Lubricate the bearing as recommended by the manufacture before assembly. Most of the bearings need no lubrication. If required, a drop of light oil like 3 – in – 1 oil could be used. 11. Clean the commutator surface. A black carbon deposit could be removed by CTC. Seat the bushes properly over the commutator. Check for adequate length of brushes to exert spring pressure. If the brush length is shorter by 1 / 3 of its original length it is better to replace with the brushes of the same grade and size. The new brush has to be bedded in the commutator properly. 12. Assemble the motor and tighten the terminal screws. 13. Assemble the blade with the jar and nylon coupling at the bottom. 14. Connect the motor to the supply and start the mixer. 15. Observe the working of the mixer for smooth running. TABLE 2 Date of Servicing Insulation resistance before varnishing / heating Insulation resistance after varnishing / heating Details for repair and replacement Between terminal and body Between armature and field Between terminal and body Between armature and field Name of the Customer … ... … … …. Address … ... … … …. Name of the appliance … ... … … …. Serial No. … ... … … …. Wattage … ... … … …. Current… ... … … …. Voltage… ... … … …. Supply … ... … … … … … … … … Make… ... … … …. … Date of Servicing Customer’s Complaint Defect Noticed by visual inspection Details of repair and replacement
117 Task 2: Repairing of mixer Listen to the complaints of the customer / user and other in the maintenance card (Table 1) 01. Common complaints are listed in the troubleshooting along with reason for the possible cause and the active action to be taken. 02. Inspect visually the following parts for trouble.  Power cord and plug  Terminal connections at the switch (back cover to be opened)  Couplings  Freeness of the shaft  Burnt smell or discolouring of windings 03. Conduct the continuity and insulation tests and enter the values in Table 2. Ascertain the area of problem by analyzing the customer’s complaint, visual inspection and test results. (Refer to the maintenance card.) 04. Troubleshoot the mixer following the hints given in the troubleshooting chart. 05. After assembling the mixer conduct the continuity and insulation test. Enter the values in the maintenance cards given earlier. 06. After satisfactory values of the test are obtained connect the mixer to the supply, and test run. TROUBLE SHOOTING CHART Problem Possible Cause Corrective Action Mixer does not run a. Overload trip might have tripped. b. No power at the outlet c. Defective power cord or plug. d. Locked shaft. e. Worm out brushes. f. Open circuited. a. Reset the overload relay and advice the customer not to overload the mixer in the future. b. If the mixer is running in your shop but not running at the customer’s house ask the customer to get the socket repaired. c. Test, repair or replace the power cord / plug. d. Unplug the supply and try to rotate the shaft by hand. Clean the bearings; lubricate the bearings as advised by the manufacturer. If the shaft is still tight, replace it with suitable bearings. The shaft might have got bent. Replace the shaft or armature assembly. e. Replace the brushes and loose springs. f. Check the field and armature windings if found defective get it rewound. Blows fuse when switched on a. Shorted power cord. b. Locked shaft. a. Replace the cord. b. As in ‘d’ above.
118 c. Defective armature or field coils d. Poor insulation resistance. e. Low capacity fuse. c. Test the windings for short, if short is found rewind. d. Check, test and repair. e. Check the capacity of the fuse against the mixer rating. Erratic operation and speed. a. Defective cord. b. Loose connection at socket or plug or at switch terminals. c. Poor spring tension or worn out brushes. d. Defective switch a. Check the cord for intermittent break. Repair or replace. b. Check and tighten the connections. c. Check, repair or replace. d. Replace the switch. Slow speed with break power a. Wrong material or too much quantity loaded for mixing. b. Jammed rotor. c. Tight blade assembly d. Worn out brushes or loose spring. e. Bent shaft. f. Partially shorted or grounded winding or poor insulation resistance a. Verify from the customer about the load and advise accordingly. b. Rotate by hand. If found tight, clean the bearing and lubricate it. If it is found still tight, change the bearings or check for bent shaft. c. Check the spring, washer and assembly. Repair or replace. d. Check, repair or replace. e. Check, repair or replace f. Check, test and repair / rewind. Mixer runs but becomes hot a. Overloading of mixer. b. Time rating of mixer is exceeded. c. Bent shaft and rotor is rubbing the stator. d. Improper coupling. a. Bring down the load in the mixer or advise the customer to go for a higher capacity mixer. b. Check the duration the mixer is switched on by the customer and compare with the mizedr rating. Advise accordingly. c. Check, repair or replace. d. Check, repair or replace. e. Check, test and rewind.
119 e. shorted winding. Mixer is noisy a. Dry bearing. b. Loose mounting screws. c. Rotor rubbing against stator. d. Bent fan blades. e. Broken or missing gasket. a. Check and lubricate. b. Check and tighten the loose screws. c. Check the alignment and shaft for bend. Repair or replace the shaft. d. Check and straighten the blades. If not possible replace the fan blades. e. Replace Motor runs on one speed only a. Check the speed selector switch connections and function of switch b. Partially burnt out field winding. a. Repair or replace the switch b. Test with multimeter. Repair or rewind. Bad sparking at motor brushes a. Struck or worn out or loose brushes b. Pittings or uneven commutator surface. a. Check, reshape the brushes, replace the springs or reposition the brushes for proper tension. b. Use sandpaper or turn the commutator on a lathe. Mixer produces shock a. Water leaking and coming in contact with live terminals. (Double insulated misers with plastic body and two pin plug. No earth connection) b. Vent hole in the mixer body clogged. c. Damaged power cord. d. Absence of earth connection. e. Live parts coming in contact with metal body. a. Check the drain hole in the coupler head assembly for blockage. Check the jar examination for leakage due to lose shaft or worn out bearing, ebonite washer breakage. Repair or replace. b. Clean the vent hole. c. Check and replace. d. Check the earth connection in the mixer motor, power cord and at socket. Repair and re do the earth connection. e. Check, repair and in contract with recheck with a megger. Smoke coming from coupling a. Improper seating between couplings. a. Check whether male and female parts of the coupling are properly seated. If not check the assembly. Include additional washers in the detachable blade assembly to make proper seating between couplings. b. Check and change the coupling.
120 b. Worn out coupling. c. Misaligned coupling. c. Check the motor assembly and align.
121 NAME OF THE EXPERIMENT Assembling and repair of electric kettle LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Assemble electric kettle  Repair the electric kettle  Understand the function of emersion rod  Repair emersion rod TOOLS REQUIRED  Heating element  Screwdriver EQUIPMENT/MACHINE  Emersion rod MATERIALS REQUIRED  Nuts  Emersion rod of 500W, 750W and 1000W  Asbestos sheet  Washer, bolts, wires  Thermostat switch PROCEDURE AND OBSERVATION 1. A stainless steel kettle is taken 2. Emersion rod (heating element) is fixed inside the kettle with the help of nut. Washer is also fixed to prevent leakage of water. 3. Lead is connected flow of electric current 4. A round size of asbestos sheet is kept over the heating element SAFETY PRECAUTION Washer should be tightly fitted with the nut to avoid the leakage of air and water, otherwise heating element will be fused.
Assam Nagaland Manipur Mizoram Tripura Arunachal Pradesh Nagaland Manipur Mizoram Tripura Arunachal Pradesh Sikkim Nepal Jammu and Kashmir Himachal Pradesh Punjab Haryana Rajasthan Gujrat Madhya Pradesh K e r a l a Goa Goa Andhra Pradesh Orissa West Bengal Jharkhand Uttar Pradesh Delhi Chattisgarh Meghalaya Bihar Tamil Nadu Karnataka Maharastra Andhra Pradesh Orissa West Bengal Jharkhand Uttar Pradesh Chattisgarh Meghalaya Bihar Tamil Nadu Karnataka Maharastra Chennai (2) Bangalore (2) Jumaikella Hyderabad (2) Chinchwad Delhi (2) Lucknow Bhubaneswar Ranchi Kolkata Shillong Patna Purnea Brahmapur Rajam Vijayawada Madurai Tirunelveli Kanyakumari Uttarakhand Thank You For further information please contact us: in.seif.etp@in.schneider-electric.com www.schneider-electric.co.in

More Related Content

PDF
92 electrical interview questions and answers
byElectricalCareer66
 
PPSX
Module-4-Electrical Safety in industrial safety
bysrujanmoily
 
PDF
Chapter 4 electrical-auxiliary_systems
byJothimanikkam Somasundaram
 
PDF
A study on IEC 60947- 2 amendments
byricha diptisikha
 
PDF
Iec standards
byRaymund Cortez
 
PDF
Building Electrical System Design & Installation
bysymbo111
 
PDF
Typical Electrical Design philosophy.
byWambasi Fred
 
PPTX
Live Line Maintenance
byGAURAV KUMAR
 
92 electrical interview questions and answers
byElectricalCareer66
 
Module-4-Electrical Safety in industrial safety
bysrujanmoily
 
Chapter 4 electrical-auxiliary_systems
byJothimanikkam Somasundaram
 
A study on IEC 60947- 2 amendments
byricha diptisikha
 
Iec standards
byRaymund Cortez
 
Building Electrical System Design & Installation
bysymbo111
 
Typical Electrical Design philosophy.
byWambasi Fred
 
Live Line Maintenance
byGAURAV KUMAR
 

What's hot

DOCX
Interlocking on switchgear principles
byBryan Johnson
 
PDF
Electrical SUBSTATION ppt
byTanvirkabirShishir
 
PDF
Chapter 01- High Voltage Engineering Introduction
byMUET SZAB Campus Khairpur Mir's Sindh Pakistan
 
PPT
Protection basic
byBHAGWAN PRASAD
 
PPS
Electrical wiring domestic and industries
byPavan Kumar Mallepoola
 
PPTX
Domestic wiring
byVima Mali
 
PPTX
Equipment protection
bySlides Hub
 
PDF
Transformer vector group_test_conditions
bySARAVANAN A
 
PPTX
Three phase transformer
byMuhammadhamad24
 
PPT
Switchyard final
byHAIDER ALI
 
PPTX
Relays and its types - complete guide
bySlides Hub
 
PDF
Motors
byKundan Parmar
 
PPTX
Supports of overhead line
byShreyansha Sonwane
 
PPTX
Laying of Underground Cables.pptx
byDrAkankshaSharma4
 
PPTX
Scope of the Electrician trade
byKISHAN PATEL
 
PDF
Practical handbook-for-relay-protection-engineers
bySARAVANAN A
 
PPTX
Industrial wiring
byRanjitKumar Parmar
 
PPTX
Electric traction system
byAmitKumar6931
 
PPTX
Vacuum circuit breaker selection of circuit breakers
byshubham_bharadia
 
PPTX
Poles and towers
byGas & Oil Pakistan Ltd.
 
Interlocking on switchgear principles
byBryan Johnson
 
Electrical SUBSTATION ppt
byTanvirkabirShishir
 
Chapter 01- High Voltage Engineering Introduction
byMUET SZAB Campus Khairpur Mir's Sindh Pakistan
 
Protection basic
byBHAGWAN PRASAD
 
Electrical wiring domestic and industries
byPavan Kumar Mallepoola
 
Domestic wiring
byVima Mali
 
Equipment protection
bySlides Hub
 
Transformer vector group_test_conditions
bySARAVANAN A
 
Three phase transformer
byMuhammadhamad24
 
Switchyard final
byHAIDER ALI
 
Relays and its types - complete guide
bySlides Hub
 
Motors
byKundan Parmar
 
Supports of overhead line
byShreyansha Sonwane
 
Laying of Underground Cables.pptx
byDrAkankshaSharma4
 
Scope of the Electrician trade
byKISHAN PATEL
 
Practical handbook-for-relay-protection-engineers
bySARAVANAN A
 
Industrial wiring
byRanjitKumar Parmar
 
Electric traction system
byAmitKumar6931
 
Vacuum circuit breaker selection of circuit breakers
byshubham_bharadia
 
Poles and towers
byGas & Oil Pakistan Ltd.
 

Similar to Schneider electrical handbook

DOCX
EIM7 week 1- DLL.docx
byRaffyServano1
 
PDF
EIM Exploratory's DLL (Lesson 1 _LO1-LO2 Week 1).pdf
byMatthew Angelo Gamboa
 
PDF
EIM Exploratory's DLL (Lesson 1 _LO1-LO2 Week 1).pdf
byAlgen4
 
PPTX
4.5 Safety measures at Home and Industry.pptx
bykarthikeyanS725446
 
PPTX
MY 1ST PPT IN IA 9 PPT APPLIED ELECTRICAL.pptx
byFryanGabuatJavilinar
 
PDF
K_to_12_Basic_Education_Curriculum_Techn.pdf
byPeteAlvinVilaRivas
 
PDF
K to 12_electrical_installation_and_maintenance_learning_module
byA J
 
PDF
K to 12_electrical_learning_module
byArthurManalo1
 
PDF
K to 12 electrical learning module
byNoel Tan
 
DOCX
Module 5 module 3 draft electrical and electronic layout and details
byGilbert Bautista
 
DOCX
Module 5 module 3 draft electrical and electronic layout and details
byGilbert Bautista
 
PDF
Module5 module3draftelectricalandelectroniclayoutanddetails-140806055304-phpa...
byJicelleBayan
 
PPT
CHAPTER 1 ELEC TP.ppt
bynassim46
 
PPT
CHAPTER 1 ELEC TP.ppt
byssuser28b150
 
PDF
Commissioning Testing And Maintenance (M'sia) - Arifin
byMd Arifin
 
PDF
Electrical Installation Work 4th Edition Brian Scaddan Ieng Miie Elec
byzeeyahrosney59
 
PPTX
Scope of work
bySaptarshi Das
 
PDF
K to 12 Electrical Learning Module
byDr. Joy Kenneth Sala Biasong
 
PDF
Electronics en engineering-basic-vocational-knowledge
bysandeep patil
 
KEY
Senior Grad Project Slides
by101650
 
EIM7 week 1- DLL.docx
byRaffyServano1
 
EIM Exploratory's DLL (Lesson 1 _LO1-LO2 Week 1).pdf
byMatthew Angelo Gamboa
 
EIM Exploratory's DLL (Lesson 1 _LO1-LO2 Week 1).pdf
byAlgen4
 
4.5 Safety measures at Home and Industry.pptx
bykarthikeyanS725446
 
MY 1ST PPT IN IA 9 PPT APPLIED ELECTRICAL.pptx
byFryanGabuatJavilinar
 
K_to_12_Basic_Education_Curriculum_Techn.pdf
byPeteAlvinVilaRivas
 
K to 12_electrical_installation_and_maintenance_learning_module
byA J
 
K to 12_electrical_learning_module
byArthurManalo1
 
K to 12 electrical learning module
byNoel Tan
 
Module 5 module 3 draft electrical and electronic layout and details
byGilbert Bautista
 
Module 5 module 3 draft electrical and electronic layout and details
byGilbert Bautista
 
Module5 module3draftelectricalandelectroniclayoutanddetails-140806055304-phpa...
byJicelleBayan
 
CHAPTER 1 ELEC TP.ppt
bynassim46
 
CHAPTER 1 ELEC TP.ppt
byssuser28b150
 
Commissioning Testing And Maintenance (M'sia) - Arifin
byMd Arifin
 
Electrical Installation Work 4th Edition Brian Scaddan Ieng Miie Elec
byzeeyahrosney59
 
Scope of work
bySaptarshi Das
 
K to 12 Electrical Learning Module
byDr. Joy Kenneth Sala Biasong
 
Electronics en engineering-basic-vocational-knowledge
bysandeep patil
 
Senior Grad Project Slides
by101650
 

More from Ramesh Meti

PPT
Motors and motor starters
byRamesh Meti
 
PPT
Dc motor
byRamesh Meti
 
PPT
Dc gen
byRamesh Meti
 
PPT
Dc gen
byRamesh Meti
 
PPTX
04 universal motor
byRamesh Meti
 
PPT
03 presentation 01 dc motors
byRamesh Meti
 
PPTX
01 dc motors
byRamesh Meti
 
PDF
Excell%20basic%20training(3) 143
byRamesh Meti
 
PDF
Excel%20basic%202 123
byRamesh Meti
 
PDF
Gulbrga history
byRamesh Meti
 
PDF
Gulbrga history
byRamesh Meti
 
PDF
Gulbarga dist details
byRamesh Meti
 
PDF
70 village-accountant-posts-advt-details-mysore-district (1)
byRamesh Meti
 
PDF
Vihan mcb-pricelist
byRamesh Meti
 
PDF
Schnieder mccb li st
byRamesh Meti
 
PDF
Schneider electrical mcb ,mccb ..
byRamesh Meti
 
PDF
Maru electrical mcb, mccb..
byRamesh Meti
 
DOCX
Tips to save energy
byRamesh Meti
 
PDF
7.reflective embroidery-on-linemen-shirts
byRamesh Meti
 
PDF
1.guidelines
byRamesh Meti
 
Motors and motor starters
byRamesh Meti
 
Dc motor
byRamesh Meti
 
Dc gen
byRamesh Meti
 
Dc gen
byRamesh Meti
 
04 universal motor
byRamesh Meti
 
03 presentation 01 dc motors
byRamesh Meti
 
01 dc motors
byRamesh Meti
 
Excell%20basic%20training(3) 143
byRamesh Meti
 
Excel%20basic%202 123
byRamesh Meti
 
Gulbrga history
byRamesh Meti
 
Gulbrga history
byRamesh Meti
 
Gulbarga dist details
byRamesh Meti
 
70 village-accountant-posts-advt-details-mysore-district (1)
byRamesh Meti
 
Vihan mcb-pricelist
byRamesh Meti
 
Schnieder mccb li st
byRamesh Meti
 
Schneider electrical mcb ,mccb ..
byRamesh Meti
 
Maru electrical mcb, mccb..
byRamesh Meti
 
Tips to save energy
byRamesh Meti
 
7.reflective embroidery-on-linemen-shirts
byRamesh Meti
 
1.guidelines
byRamesh Meti
 

Recently uploaded

PPTX
battery energy storage system (BESS).pptx
bymanish99skp
 
PDF
Software Engineering : Process Model
byGunjalSanjay
 
PDF
Julian Kalac -GEN AI inventive solution Automated SOC Report Processing .pdf
byJulian Kalac P.Eng
 
PDF
BCS402 MICROCONTROLLERS MODULE 1
byAbhijith L Kotian
 
PDF
E-Commerce and Web Engineering Presentation (Python, Django Project) A Online...
by Zubayer Talukder Rabbii
 
PDF
Software Engineering Perspective Process Models
byGunjalSanjay
 
PPTX
lecture 1 Machine tools the introduction
bypushkarkamble2
 
PPTX
An Early Production Facility (EPF) is a modular, temporary system for rapidly...
byDrAdelSalem1
 
PPTX
FROM MEASUREMENT TO MEANING : Metrology-Driven Battery Testing for Reliable ...
byRunjhunDutta
 
PDF
Software Engineering :Software Engineering Practice
byGunjalSanjay
 
PPTX
Diagram of Control Valves used in Industrial Fluid Power.pptx
bySBM Polytechnic
 
PDF
22PEOIT4C Artificial Intelligence unit 3 QB Final.pdf
byGuru Nanak Technical Institutions
 
PDF
22PEOIT4C_Artificial_Intelligence_UNIT_III_Notes_Final
byGuru Nanak Technical Institutions
 
PPTX
24ME402-ENGINEERING MATERIALS AND METALLURGY --- UNIT-II
byDJAGADEESH1
 
PPTX
Coagulation, flocculation and settling.pptx
byChemical Engineering Dept. NIT Rourkela-769008, Odisha, India
 
PDF
DevArc 2026 Finale GDG on Campus MM(DU).pdf
byhemish04082005
 
PPTX
Exploring Exhaustivity in Wh-Questions Through Analysis of Natural Language U...
byraghabBsingh
 
PPTX
L1 (1) Agricultural informatics and artificial intelligence.pptx
bymanoiitkgp
 
PDF
Taykon Proses -ENG- Process Equipment Manufacturer
byTAYKON
 
PDF
Earths-Structure-and-Composition_20260127_110958_0000.pdf
byabdurasabarfaki
 
battery energy storage system (BESS).pptx
bymanish99skp
 
Software Engineering : Process Model
byGunjalSanjay
 
Julian Kalac -GEN AI inventive solution Automated SOC Report Processing .pdf
byJulian Kalac P.Eng
 
BCS402 MICROCONTROLLERS MODULE 1
byAbhijith L Kotian
 
E-Commerce and Web Engineering Presentation (Python, Django Project) A Online...
by Zubayer Talukder Rabbii
 
Software Engineering Perspective Process Models
byGunjalSanjay
 
lecture 1 Machine tools the introduction
bypushkarkamble2
 
An Early Production Facility (EPF) is a modular, temporary system for rapidly...
byDrAdelSalem1
 
FROM MEASUREMENT TO MEANING : Metrology-Driven Battery Testing for Reliable ...
byRunjhunDutta
 
Software Engineering :Software Engineering Practice
byGunjalSanjay
 
Diagram of Control Valves used in Industrial Fluid Power.pptx
bySBM Polytechnic
 
22PEOIT4C Artificial Intelligence unit 3 QB Final.pdf
byGuru Nanak Technical Institutions
 
22PEOIT4C_Artificial_Intelligence_UNIT_III_Notes_Final
byGuru Nanak Technical Institutions
 
24ME402-ENGINEERING MATERIALS AND METALLURGY --- UNIT-II
byDJAGADEESH1
 
Coagulation, flocculation and settling.pptx
byChemical Engineering Dept. NIT Rourkela-769008, Odisha, India
 
DevArc 2026 Finale GDG on Campus MM(DU).pdf
byhemish04082005
 
Exploring Exhaustivity in Wh-Questions Through Analysis of Natural Language U...
byraghabBsingh
 
L1 (1) Agricultural informatics and artificial intelligence.pptx
bymanoiitkgp
 
Taykon Proses -ENG- Process Equipment Manufacturer
byTAYKON
 
Earths-Structure-and-Composition_20260127_110958_0000.pdf
byabdurasabarfaki
 

Schneider electrical handbook

  • 1.
    Electrician Training Program,India Domain Handbook for Assam Nagaland Manipur Mizoram Tripura Arunachal Pradesh Nagaland Manipur Mizoram Tripura Arunachal Pradesh Sikkim Nepal Jammu and Kashmir Himachal Pradesh Punjab Haryana Rajasthan Gujrat Madhya Pradesh K e r a l a Goa Goa Andhra Pradesh Orissa West Bengal Jharkhand Uttar Pradesh Delhi Chattisgarh Meghalaya Bihar Tamil Nadu Karnataka Maharastra Andhra Pradesh Orissa West Bengal Jharkhand Uttar Pradesh Chattisgarh Meghalaya Bihar Tamil Nadu Karnataka Maharastra Chennai (2) Bangalore (2) Jumaikella Hyderabad (2) Chinchwad Delhi (2) Lucknow Bhubaneswar Ranchi Kolkata Shillong Patna Purnea Brahmapur Rajam Vijayawada Madurai Tirunelveli Kanyakumari Uttarakhand Electrical Training Knowledge Partner Schneider Electric Sponsored by: Schneider Electric India Foundation
  • 2.
    PREFACE In modern educationphraseology, the word “facilitator” is increasingly taking the place of “teacher”. As the word suggests, a facilitator is a person who facilitates, or who makes things easier. To a large extent, the success of the training program – or any other classroom-based program for that matter depends on the trainers’ ability to assume the role of a facilitator. The ideal facilitator… … connects with each of his students, and not just a few “good” ones … is a keen learner himself … understands his/her students, and not judge them …does not hesitate in giving candid feedback to the learners, but words his/her feedback very carefully … has enormous patience … knows his/her subject very well, but never flaunts what he knows … is willing to admit his/her shortcomings in front of the class … progressively makes himself/herself redundant in the classroom process Different Strokes for Different Folks A very important aspect of good facilitation is the facilitator’s ability to look at each learner as a unique, independent individual, with specific learning needs and capacity. The facilitator should make the effort of getting to know each of his/her learners at a personal level – to find out the background, the environment at home, likes and dislikes, what makes the person tick. He/she should objectively assess the initial (baseline) level of each learner, instead of having a “general” impression about the whole group. Armed with this information, the facilitator can use different approaches with different learners. A peep into the Classroom What to expect in a classroom for adults Perhaps the biggest mistake that some teachers tend to make in an adult classroom is to treat the learners not as adults but as children. This may happen when the teacher is older than the students in general, or when the teacher is used to taking classes for younger children. Learners above the age of 18-20 are sufficiently mature in their worldview and understanding to be treated as young adults – a condescending attitude towards them would hinder the learning process at the outset.
  • 3.
    Specifically, the teacherof an adult classroom should remember that adult learners… can decide for themselves what is important to be learned. need to validate the information based on their beliefs and experience. expect what they are learning to be immediately useful. have much experience upon which to draw – may have fixed viewpoints. have a significant ability to serve as a knowledgeable resource to the teacher and fellow learners. Key challenges in a Classroom While the points listed above bring out some of the ways in which a classroom with adult learners can be different from one with children, there are also several things common to all classrooms. Here’s a shortlist of some of the key challenges teachers face in a classroom:  Lack of interest  Lack of confidence  Unwillingness to participate  Domination by one or two learners  Variation in levels across learners  Irregular attendance  Slow learners Most of these challenges can be effectively tackled by following the principles outlined in the earlier section on facilitation. Also, handling these situations comes with practice – as a teacher spends more time in the classroom with a varied group of learners, he would become more and more adept at handling challenging situations inside the classroom.
  • 4.
    This handbook containsfour sections: Section 1: Theory Pages 1-42 Section 2: Basic Electricals Pages 43-70 Section 3: Wiring Pages 71-100 Section 4: Repairs & Maintenance of Home Appliances Pages 101-121
  • 5.
    CONTENT - Theory ChapterName of the Topic Page No Day 1 Tools - uses and safety 1 2 2 Symbols – Switches and sockets 2 5 3 Safety Precautions – Getting shock, prevention, fuse, MCB, Fire, Earthing 4 6 4 Work, Power, Energy – Voltage, current, Resistance , Watts, KWH etc 10 8 5 Ohm’s Law – Series and Parallel circuits, comparisons 12 7 6 Conductors and Insulators – Introduction, types, materials, wires, gauges, cables 14 30 & 31 7 Electrical Accessories – Switches, sockets etc 18 9 8 Wiring system – Types, testing, earthing, distribution etc 21 16 9 Electricity – History Sources, effects and uses 27 4 10 AC/DC/ Polyphase - Basics, difference, connections, comparisons, advantages 30 38-40 11 Generators and Motors – Principles, parts, uses, functions, starters, general maintenance 32 55-56 12 Transformer – Principle, trypes, parts, cooling methods and maintenance 39 57-58 13 UPS – basics, connections and maintenance 41 59-60
  • 6.
    CONTENT - Practical Exp No. ExperimentPage no Day 1 Measurement of wire sizes 43 1 2 Skinning cable ends 45 3 3 Making of simple twist joints 47 3 4 Making of Tee joint in stranded conductors 49 3 5 Soldering of the joints 51 3 6 Termination of cable ends 53 3 7 Crimping of cable ends 54 3 8 Identify the phase and neutral in single phase AC supply 56 4 9 Identify, dismantle, sketch and assemble electrical accessories 58 4 10 Study of multi meter 61 4 11 Making of Test board 63 4 12 Assemble of single T/L fitting 65 10 13 Assemble of twin T/L fitting 67 11 14 One light control by one switch 69 12 15 One socket control by one switch 70 13 16 Complete wiring of a room 71 14 17 Two light control by two switches 73 15 18 Making of pipe earthling connection 74 16 19 Fixing of tube light fitting 77 17 20 Complete wiring of 1BHK House 79 18-19 21 Fixing of a ceiling fan controlled by switch 81 20-21 22 Fan control by regulator through switch 86 22 23 House Power socket controlled by DP switches 88 23 24 Complete wiring of 2BHK 89 24-26 25 Five lights controlled by five switches 90 27 26 Telephone and cable socket 91 28-29 27 Complete wiring of 3BHK House 92 30-31 28 Hotel and mini lodge wiring of six rooms 93 32-34 29 Wiring of corridor lighting 95 35-37 30 Knowledge of DOL starter 96 41-43 31 Manual star delta starter 99 44-46 32 Assemble and repair of non-automatic iron 101 47 33 Repair of automatic electric iron 103 48 34 Service and repair of a wet grinder 106 49 35 Service and repair of a Geyser 109 50 36 Fixing and repair of table fan 112 51-52 37 Assemble and repair of Food mixer 115 53 38 Assemble and repair of kettle 121 54
  • 7.
    1 CHAPTER I: TOOLS Identification,uses and safety Introduction A good craftsman needs good tools to be able to do his work well. It is therefore important that we know about different tools used in electrical applications, as well as power tools for industrial purposes. Aim To gain an understanding of various electrical tools. Objectives At the end of this class, you should be able to:  Name the basic hand tools and their classification.  Give full specification of each tool.  Explain their uses.  Demonstrate their application. Types of Tools  Basic tools: Combination pliers, screw driver set, line tester, nose pliers, ball pane, cross pin, sledge hammers, electric knife, etc.  Measuring tools: Measuring tape, analog meters, digital meters, wire gauge, tri- square, etc.,  Cutting & chasing tools: Hand saw, tennon saw, knife, chisels, drilling tools, etc.  Power tools: Drilling machine, chasing machine, cutting machine, demolition machine, etc.  Testing tools: Test lamp, digital multimeter, clamp meter, line tester 500v, test lamp, etc. Tool specifications (To be explained tool- wise, along with purpose and precautions to be followed). Demonstration (The trainer should apply the „Why, What, When, Where, Who, Which and How‟ technique to activate the aspirants‟ minds). Review / Assessment  List out the tools used by an MSW technician.  Explain the uses of various tolls and precautions to be followed.  Describe test lamp, digital multimeter, clamp meter, line tester, etc.  Explain the uses of power tools. Reference Basic Electrical Engineering by Mittal & Mehta
  • 8.
    2 CHAPTER II: SYMBOLS Introduction Inany complicated circuit diagram of the electrical installation in a multi-storied building / complex / industrial workshop, the electrical circuits consists of fixtures, fittings, equipment and machinery as a main utility and are connected to various protective and operational devices with / without measuring devices for easy and efficient operation. In electrical engineering, it is a common practice to employ graphical symbols to denote the various means and devices used when making diagrams of connections. These symbols serve the purpose of expressing the component / equipment of fixtures for easy symbolic representation. Without knowing these symbols it is difficult to read the circuit diagram giving the plan of electrical installation or connection. The standard symbols are listed in Code 2032 (Parts 1 to 18). Therefore as an electrical technician you should be able to draw and identify symbols.
  • 9.
  • 10.
    4 CHAPTER III: SAFETYPRECAUTION Getting shock, prevention, fuse, MCB, Fire, types, causes, earthing Introduction Electricity helps us in many ways. But it can take a lot more than it gives us, and can be dangerous if it is not treated properly. So we need to be very careful while working with the live supply. Aim To understand electrical safety, electrical shock and First Aid Objectives After completing this course, you should be able to:  Explain the safety precautions  Know precautions to be taken to prevent electric shock.  Explain causes of electric shocks, effects and shock treatment.  Demonstrate Cardio-Pulmonary Resuscitation (CPR) Safety Precautions  Careful handling of electrical appliances, using insulated hand tools, using correct rating fuses, effective earthing.  Metallic parts, using of hand gloves, using rubber mat, never tamper unnecessarily with live lines and never use damaged appliances. Causes of Electric Shock  Carelessness  Accidental  Over confidence  Lack of awareness / ignorance  Natural causes (lightning etc.) Effects of Shock on the Human Body On the brain, body, kidney, etc. (refer to text books) The Severity of a Shock Depends on:  Duration of current flow  Amount of current  Path of flow of current -location  Type of energy and line voltage, etc. An electric shock occurs by touching:  Phase and natural simultaneously  Phase conductor and standing on ground  A metallic part, when current is leaking. Treating Shock Cardio-Pulmonary Resuscitation (CPR) (Trainer to give live demonstration) Safety experts prefer the use of mouth-to-mouth resuscitation because it moves the largest volume of air into and out of the victim‟s lungs. The steps of application are described below:
  • 11.
    5 1. The victimshould be laid on his back with his head turned to one side and his mouth cleared of any saliva or foreign objects (e.g. dental plates) by insertion of the operator‟s thumb. Waste no time! 2. His head is then placed as far back as possible so that his neck is extended, chin toward ceiling. Mouth should drop open. 3. The operator uses one hand to support the victim‟s neck to keep head in proper position and then closes the victim‟s nose with his other hand (Figure 2). 4. After taking a deep breath, the operator places his mouth completely over the victim‟s mouth with airtight contact. The victim‟s mouth should not be held open too wide as it must be totally covered by the operator‟s lips. 5. The operator then breathes or blows into the victim‟s mouth, forcefully for adults and gently for children. The victim‟s chest should be watched, and as soon as it rises, the blowing should be stopped and the operator‟s mouth quickly removed from the mouth of the victim, allowing him to exhale passively. 6. The jaw must be held in an elevated position on both the inspiration and expiration phases, preferably by supporting the victim‟s neck. 7. If the chest does not rise, the position of the head and jaw should be improved and the blowing done more forcefully. If the victim‟s lungs are still not ventilated, his airway may be obstructed. Try the Heimlich Maneuver described on the wall card. 8. The cycle of inhalation and exhalation should be repeated 12 times per minute for adults. 9. If the victim‟s stomach swells during resuscitation, air may be entering it. This may be corrected by the operator gently pressing on the victim‟s stomach during exhalation. (Allow each aspirant to practice CPR) Review / assessment  Causes of electric shock  Effects of electric shock  CPR and its administration Reference First Aid (guest lecture by a doctor) Skill Cardio-Pulmonary Resuscitation (CPR)
  • 12.
    6 CAUSES OF ELECTRICFIRE, AND EQUIPMENT USED TO CEASE FIRE Introduction When a conductor carrying electric current gets overloaded, it heats up and softens the insulating cable. This may lead to a short circuit and fire. It is therefore important that we understand various types of fire and how to put them out with fire extinguishers. Aim To understand various causes / types of fire and how to extinguish them Objectives At the end of this lesson you should be able to:  Understand what is fire and its chemistry  Understand various causes of fires  Know their classification and mechanism involved  Use the right fire extinguisher Causes of electric fire Fire is a chain of chemical reaction, caused by combustion of inflammable material producing heat, light and smoke. The reasons for a fire could be:  Improper / substandard cables for wiring  Short circuits  Overloading the equipment  Maintenance negligence  Inadequate / poor insulation  Lightning Chemistry of fire The main components of fire are: Oxygen, Fuel and Heat (energy) Classification of fires S. No Type of fire Name of fire Source Fire extinguishers used 1 Class A Solid fires Wood, cloth paper A class fire extinguishers 2 Class B Liquid fire Petrol, fuel Dry Chemical Powder (DCP) 3 Class C Gas fire LPG gas Dry Chemical Powder (DCP) 4 Class – D Metal Fire Sodium, Magnesium ABC Fire extinguishers 5 Electrically Started Fires (ESF) Electrical Fire Electrically Starts ABC Fire extinguishers, CO2 Gas
  • 13.
    7 Types of FireExtinguishers Soda acid, Water-CO2, Form-type, Dry Chemical Powder (DCP), CO2 gas, ABC Powder Extinguisher Pressurizing mechanism in a Fire Extinguisher  Gas cartridge (CO2, water)  Spot pressure (soda, acid, and gas)  Stored pressure (readily available) Advantages of ABC Fire Extinguishers  Very easy to handle  Anybody can operate  Can be located at the level of pressure  Very economical and effective  Can be used for any type of fire (Class A / B / C)  Readily available with stored pressure Review / Assessment  Fire and its chemistry  Different types of fires.  Different types of fire extinguishers.  Advantages of ABC fire extinguisher.  What is stored pressure? EARTHING AND ITS METHODS (IS CODE 3043) Introduction Electricity today is playing an ever increasing role in the lives of every human being. Increased use of electricity has resulted in increased danger to human beings. When lightening occurs, it not only damages consumer‟s premises but it also destroys property and lives. So today Earthing is considered the most essential provision of any electric supply system. But unfortunately it is the most neglected aspect in house wiring and in many cases even in industrial and commercial wiring. So earthing is thus laid down as a statutory requirement in Indian electricity rules so as a trainer / trainee we need to understand
  • 14.
    8 and implement iton grounds. Hence today we discuss about Earthing. Aim To facilitate learning of Earthing and its needs through demonstration and Practical session Teaching and Learning Methodology Lecture, Video, Demo and Practical Learning Objective After completion of this session an aspirant shall be able to  Define Earthing  Explain the purpose of Earthing  Differentiate methods of Earthing and emphasis on best methods  Factors affecting the resistance and related ISI Rules Preview What is Earthing? A wire coming from the ground 2.5m to 3m deep from an electrode (Plate) is called Earthing. A wire 2.5m to 3m long connected from an electrode (plate) to the main switch board to avoid shock is called Earthing. Note: The metal plate, copper plate, rod or conductor is called as earth electrode. Purpose / Objects of Earthing  To save human life from Danger / shock  To protect large buildings and towers from lightening  To protect all machines fed from OH lines from lightening arresters  To maintain the line voltage  To provide easy return path for leakage current  Good Earthing is that which gives low resistance and enables smooth flow of heavy current Methods of Earthing There are mainly two methods of Earthing. They are: a. Plate Earthing (most common and effective method) b. Pipe Earthing ISI Rules  The standard Earthing code is IS 3043  The Earth pit must be 1 ½ m distance from the building wall  The earth wire must be of the same material as that of the electrode used  The cross sectional area of the earth wire should not be less than 8 SWG  The size of the earth conductor should not be less than half the size of the line conductor  All the joints must be properly joint, bolted, soldered or brazed  All the metal parts, motors, generators and other appliances must be properly connected by the earth conductor  All the third pin of sockets must be connected to earth conductor  Every stay wire must be Earthed Latest Trends Mat Earthing
  • 15.
    9 Conclusion It is verynecessary to know about Earthing and to motivate and educate the consumer about the need for it. Summary / Assessment a. Define the Earthing and explain the purpose? b. Which type of Earthing is effective? Why? c. How do you reduce resistance of an earth electrode? d. List down the IS rules related to good Earthing. FAQ Why are charcoal and salt used for Earthing? Is copper Earthing is effective? Reference General Information, ICPCI Hand book Practical Earthing and testing of earth resistance.
  • 16.
    10 CHAPTER IV: WORK,POWER AND ENERGY Voltage, current, Resistance, Watts, KWH etc Introduction It is commonly understood that „work‟ is accomplished when „energy‟ is expended for the purpose. It is therefore necessary to understand the link between work, power and energy. Aim To understand the concept of work, power and energy Teaching and Learning Methodology Lecture, charts, practical and classroom training Objectives At the end of this session the aspirant should be able to:  Define work, power and energy and their units.  Distinguish between work, power and energy.  Calculate the power and energy consumption. Work When force is applied on a body, and the body moves in the direction of the force, work is said to have been done. Work (W) = Force (F) x Distance (D) The unit of work is joule (MKS system) or erg (CGS system). The unit of force is Newton in MKS system. Power Power is the rate of doing work. Power (P) = Work done (W) / Time taken (T) The unit of power is joules / second or watts / second. I kilowatt (kW) = 1000 w Another unit of power is hp; 1 hp = 746 w, or 1.34 hp in MKS system; 1 kW = 1.36 hp Energy Energy is the capacity for doing work. Energy exists in several forms, which may be interchanged. 1 joule = 1 Newton / meter A small unit of power is watt / second A bigger unit of power is kwh (also called (botu); 1 botu = 1000 w or 1 kwh = 36,00,000 joules Energy Calculation Calculate the total load consumption for an electric installation consisting of the following: S. No. Name of point No. of points Load 1 Lamps 10 100 2 Ceiling fans 8 75 3 Electric heater 1 1500 4 Motor 1.5 hp 1 - Total load Calculate the total units consumed in a month, when the cost of energy is First 200 units @ Rs.1.50 / unit; Second 200 units @ Rs.2.00 / unit; Rest @ Rs.2.50 / unit
  • 17.
    11 Solution S. No. Name of pointNo. of points Load Total hours Total 1 Lamps 10 100 8 8000 wh 2 Ceiling fans 8 75 10 6000 wh 3 Electric heater 1 1500 3 4500 wh 4 Motor 1.5 hp 1 (735.5 w) - 4 4413 wh Total load 22913wh / per day Energy consumed in the month = 30 x 22913 wh = 687390 wh / 1000 = 687.39 kwh Billing Calculation First 200 units = Rs.1.50 x 200 = Rs.300; Next 200 units = Rs.2.00 x 200 = Rs.400; Rest of the units = Rs. 2.50 x 287.39 = Rs.718.47. Total billing for the month = Rs.300 + Rs.400 + Rs.718.47 = Rs.1418.47 Review / Assessment  Define work, power and energy. What are their respective units?  Calculate the power and consumption of your house as per the existing rates.  What are hp, bhp and botu? Reference Basic Electrical Engineering by ML Anwani, Gupta and Mehta
  • 18.
    12 CHAPTER V: OHM’SLAW Series, parallel circuits, comparisons OHM’S LAW The Ohm‟s Law was propounded by George Simon Ohm, which defines the relationship between current (i), power (p), voltage (v) and resistance (r) I = v / r - 1 r = v / i - 2 v = i x r - 3 Ohm‟s Law states that, in any closed electrical circuit the current is directly proportional to voltage applied and universally proportional to the resistance of the circuit, temperature and other physical conditions being constant. CIRCUITS AND CONNECTIONS Introduction Line supply comes from power sources and terminates at the switch and distributed to the light points. The whole process ends with a circuit. Aim To understand various circuits and connections Teaching and learning methodology Theory, demonstration, practical and chart Objectives After completion of this session the aspirant should be able to:  Define what is an electric circuit  Understand various types of circuits  Compare Series and Parallel connections  Draw a circuit diagram and solve simple calculations Definition of circuit The path taken by an electric current is called a circuit. Circuit Components  Power source (AC / DC)  Current carrying conductor (wire)  Mechanism/ controller (switch)
  • 19.
    13  Resistance orload (consumer) Types of Circuits  Open circuit  Closed circuit  Short circuit  Leakage circuit Connections Circuits are connected in two ways: Comparison between series and parallel: Series connection Parallel connection 1. 1. 2. Current flows in single path 2. Current flows in several paths 3. Voltage is divided across each resistance v = v1 + v2 + v3 3. Voltage is constant 4. Current is constant 4. Current is divided i =i1+i2+i3 5. Total resistance is equal to the sum of individual resistance r = r1 + r2 + r3 5. The reciprocal of the total resistance is equal to the reciprocal the sum of individual resistance i.e. 1/r = 1/r1 + 1/r2 + 1/ r3 6. Fault finding is difficult 6. Fault finding is easy 7. Used for decoration purpose 7. Used for domestic purpose Note: Practical related to Series and Parallel Review / Assessment  Definition and types of circuit  Circuit components  Series and Parallel connections  Short circuit Reference Basic Electrical Engineering by Mehta Skill Making series and parallel connections Parallel connection Series connection
  • 20.
    14 CHAPTER VI: CONDUCTORSAND INSULATORS Introduction, Types, Materials, Wires, Guages Cables Introduction Conductors and insulators play a vital role in domestic / industrial wiring, including networking systems. While conductors carry the current, insulators provide safety for it. It is important to understand them well. Aim To understand conductors and insulators Teaching Learning Methodology Lecture, Demonstration and Practical Learning Objective After completion of this lesson the aspirant would be able to  Define a conductor and an insulator  Differentiate between a conductor and an insulator  State the materials used for a conductor and an insulator  Understand the properties of a conductor and an insulator and their uses Preview Conductor: A material which contains many free electrons and is capable of carrying electric current is known as a conductor. Properties of a conductor: Conductors:  Have a law specific resistance  Are mechanically rigid  Should be easily available  Should not be very expensive  Should be non corrosive  Should be ductile  Should be durable, malleable  Should have high stencil power  Should be highly conductive The common conductors used for electrical purpose are:  Silver  Copper  Bronze  Brass  Aluminum  Lead  Tin  Micromere  Tungsten  Eureka  Carbon etc. Insulators: A substance which cannot pass current through it under normal conditions is termed as an insulator. Properties of insulators: Insulators:  Should have low conductivity  Should have a high specific resistance  Should have a resistance and ability to bear high temperatures  Should have a good mechanical strength  Should be moisture resistant and water proof  Should have a high dielectric strength (voltage bearing capacity)
  • 21.
    15  Should bepermanent in nature (remain in the same state and condition regardless of the environmental conditions) The common insulation used for electrical uses:  Bakelite  Porcelain  Mica  Rubber  Fiber  Vanish  Glass  Wood  Cotton tape  PVC  Oil Classifications of cables according to the insulator used:  VIR wires  PVC wires  Flexible wires  Enameled wires  Cotton covered wires Conclusion Conductors and insulators are not only used for electrical wires but also for power generation, transmission and distribution system. Assessment / review  Define the conductor & insulator  Properties of conductor & insulator  Name different conducting & insulating materials.  Classify the cables according to the insulation use? o VIR, CTS o PVC Reference Basic electrical engineering by Mittal UNDER GROUND CABLES Introduction Electric power can be transmitted or distributed either by OHL or by underground cables. The underground cables have several advantages, the only disadvantage being the initial cost. Aim To facilitate learning about underground cables Teaching and Learning Methodology Lecture, demo and Practical Session Learning Objective After completion of this session the aspirant would know about: a. Construction of cables b. Classification of cables c. Cables used for 3 phase service d. Laying of underground cables
  • 22.
    16 Preview Underground cables An undergroundcable essentially consists of one or more conductors covered with suitable insulation and surrounded by a protecting cover. Construction of cables The various parts of underground cables are as under as shown in the picture. a. Cores or conductors b. Insulation c. Metallic sheath d. Bedding e. Armoring f. Serving Insulating material for cables The satisfactory operation of a cable depends to a great extent upon the characteristics of insulation used. The principal insulating materials used in cables are: a. Rubber b. Vulcanized Indian Rubber (VIR) c. Impregnated paper d. Varnished cambric e. Poly Vinyl chloride (PVC) Classification of cables Cables for underground service may be classified in two ways according to: 1. The type of insulating material used 2. The voltage for which they are manufactured According to the voltage 1. Low tension (LT) cable – up to 1000V 2. High tension (HT) cable – up to 11,000V 3. Super tension (ST) cable – up to 33 KV 4. Extra high tension (EHT) cable – 3 KV to 66 KV 5. Extra super voltage cable – beyond 132 KV Cables for 3 phase service 1. Better cable – up to 11 KV 2. Screened cables – 22 KV to 66 KV 3. Pressure cable – Beyond 66 KV
  • 23.
    17 Laying of undergroundcables 1. Direct laying 2. Draw in system 3. Solid system Review 1. How do you classify the cables? 2. What are the types of cables used for 3 phase system? FAQ 1. What is EHT, EST? 2. Explain the methods of cable laying? Related skill Cable jointing Reference Principles of power system
  • 24.
    18 CHAPTER VII: ELECTRICALACCESSORIES Switches, Sockets Introduction Electrical appliances occupy a prime place of importance in our life style. The usage of electricity in modern life is increasing the standard of living in almost every home. On the other hand, Electrical wiring, which is essential for these appliances to work, receives very little attention. As an electrical technician, contractor, consultant or architect we are responsible to both the builder and consumer. The reputation and success of technicians depends on the quality of wiring they door recommend. Teaching and Learning Methodology Lecture Method, Demonstration and Site visit Aim To impart knowledge and related skills to the aspirant Learning Objective At the end of this session the aspirant will know about the: a. Protection and distribution of supply system and accessories used b. Cable carrier and support system c. Different types of current carrying conductors d. Switching and terminating products e. Sensor switching etc. Preview House wiring accessories can be classified into the following categories: a. Control and distribution system b. Cable carrier and support system c. Current carrying conductors (wires) d. Switching and termination products e. Sensor Switches a. Control (Protection) and distribution system This system is used to control the main supply and distribute it to the circuits. The main protective devices used in house wiring circuits are: i. Fuses (Fuse that can be re-wired, HRC Fuses available at diff ranges [6Amp to 200Amp]) ii. ICDP, ICTP (available at 32A to 200A) iii. Miniature Circuit Breakers (available at 1A to 40A) iv. Isolator (available at 32A to 63A) v. ELCB / RCCB – (available at 32A, 40A & 63A) and MCCB above 63A All the above mentioned items are installed in control and distribution boards. The Boards are available in 1 phase, 3 phase, single door and double door as shown in the picture. b. Cable carrier and support The house wiring cable can‟t be run or laid on walls without support. Hence the wires need to be supported from the main distribution till the terminating product. The systems used to carry, support and run these wires are called cable carriers and support systems. The different systems which we adopt for the same are as follows: i. Wooden capping & casing wiring
  • 25.
    19 ii. Cleat wiring iii.Conduit wiring (open/ surface) iv. Conduit wiring (concealed) c. Different accessories available to carry wires i. PVC conduits available in 19 mm, 25 mm ii. Junction Box – 1 way, 2 way, 3 way and fan hooks iii. MS / GI conduits and its accessories such as MS inspection bend, Inspection „T‟ and „J‟ boxes etc. iv. The conduits are available in sizes of 16mm, 19mm, 25mm and 30mm and are normally of 16 SWG thickness v. Casing and capping batten patties are also available in different sizes for temporary wiring vi. House wiring cables (current carrying conductors): The cables are used to carry the current from main supply to the sub circuits or to a particular point. Earlier house wiring cables used tinned copper conductors covered with Vulcanized Indian Rubber (VIR) and CTS also called TRS. vii. House wiring cables and their historical back ground: Till 1955 : VIR – CTS cables are most commonly used for outdoor and indoor purposes 1955 : Introduction of PVC Cables as per IS-694; India started to manufacture PVC Cables indigenously 1991 : BIS started giving certification under IS 694 to copper cables viii. Common cables used for house wiring ISI recommends the use of metric system of wires as given below: a. 1.0 Sq mm b. 1.5 Sq mm c. 2.5 Sq mm d. 4 Sq mm e. 6 Sq mm f. 10 Sq mm Note: Obsolete British standard cables are 1/18, 3/20, 7/20 etc. d. Switching and terminating products All these products have certain common features like insulation bases and covers. All the house wiring cables normally terminate in: i. Switches (All types) ii. Sockets iii. Ceiling roses iv. Holders and adaptors etc. i. Switches: Switches are classified as under: 1. According to the rating – 6 A, 10 A, 16A 2. According to the connection – 1 way, 2 way and intermediate ii. Sockets: 1. According to the rating: 6A, 10A, 16A, 25A etc. 2. According to the connection: 2 pin, 3 pin, 5 pin, multi pin etc. iii. Ceiling Roses: The wiring from switch terminals is taken to ceiling roses, lamp holders and connectors. The ceiling roses are available in two types. These are 2 pin and 3 pin. iv. Holders and Adaptors: There are some other terminating products named as holder and adaptors.
  • 26.
    20 Different holders areavailable in the market: a. Angle Holder b. Batten Holder c. Pendent Holder d. Screw type / Pin type Holder etc. e. Sensor Switches: Sensor switch is also similar to the switch but it works on sensor signals. It is a small electronic circuit. The sensor switches are as under: a. Temperature sensor b. Light sensor c. Dark sensor d. Sound sensor e. Acoustic sensor f. Vibration sensor g. Altitude sensor h. PIR (Passive Infrared) etc. Personal safety and Earthing: Earthing is the most neglected aspect in house wiring and is usually considered an unnecessary expenditure. However, Earthing is the most essential safety requirement. Providing good earthing is a basic need as per Indian electricity rules under IS 3043, 1987. Electrical contractors, Electricians and wire men should ensure that they do not compromise on the safety of their clients or clients‟ families. (Earthing lesson has been covered on the video) Standby power sources: Power outages are very common in all parts of the country which is why standby power sources are very essential to fulfill the power shortage. Standby power sources may be: a. Alternators / Generators b. UPS (Uninterrupted Power Supply) system c. Inverter d. Emergency lights etc. Security and protection: Security of house hold property and lives of the residents is increasingly becoming a matter of concern. We hear of many instances where criminals have forced their entry and ransacked houses. There is, therefore, a growing need for equipment which will improve the safety and security of life and property. There are several effective alarming systems available in the market (burglar alarms, smoke detectors etc.) which are usually not preferred by the common man due to their heavy costs. Review / Assessment  Name different control and distribution system?  How can wires be carried and supported?  What are the various terminating products available in house wiring systems?  What are the different conductors used for house wiring systems?  What are the uses of sensor switches? FAQ 1. What are the different sources available for standby power? 2. What is the need for security and protection systems? Reference Hand Book ICPCI
  • 27.
    21 CHAPTER VIII: WIRINGSYSTEM Tpyes, Testing, Earthing, Distribution DIFFERENT TYPES OF WIRING SYSTEMS Introduction The good appearance of a house depends upon the house wiring system adopted and selection of branded material. Thus is the need to know about quality of the wirings and accessories being used. Teaching and Learning Methodology Lecture, Demonstration and Practical Aim To discuss about the different system of wiring Objectives After completion of this session aspirants would know about  Criteria for selecting a particular type of wiring  Customer expectations  Providing customer satisfaction  Factors that are to be considered in house wiring Preview Criteria for selecting a particular type of wiring The following points must be considered before selecting a particular wiring. 1. Durability: The wiring must be able to withstand wear & tear under any circumstances. 2. Safety: The wiring must be able to provide safety by safely concealing the wiring systems. 3. Mechanical Protection: Conduit wiring must be protected from damage through physical or natural changes during its use. 4. Appearance: Appearance is the most important aspect to consider from the architectural point of view. 5. Permanency: The wiring must not be affected by weather, smoke, dampness etc. 6. Accessibility: In the wiring system facility for the extension or renewal or attraction should provided. The wiring must be done in a way that makes distribution of power easy, without any hassles. 7. Cost: The wiring system adopted must be economically suitable to the client. Customer Expectation As technicians we must be able to predict a customer’s expectations such as  Reduction in electricity bills  Safety against electrical fire hazards  Good Earthing to avoid electric shocks  No hanging of „wire webs‟ in the house  Proper concealed wiring  No extension boxes and wires  Hassle free wiring How to provide Consumer Satisfaction Customer satisfaction can be provided by the following  Adequate number of points (comfort and safety)  Circuitry design (Safety, No over-loading)  ISI Mark ETP wires (Reliability, Safety, multi strand flexible wire, energy saving)  Higher cross sectional area of wire (Safe and energy saving)
  • 28.
    22  Derating factor(cables are derated to have the capacity to take more current than usual, i.e. one-size-up cable) – due to concealed wiring  Earthing with Copper wire(Safety against shocks) Common factors considered in house wiring  Cable selection (Voltage grade and Voltage drop, Current rating etc.)  Over loading  Circuitry design  Short circuit  Earthing  Derating etc. Specification of wiring Lighting loads (Bulb, Fans, and Fuses etc.) Medium loads (T.V., Refrigerator, Iron boxes etc.) Heavy loads (A/C, Geyser, Electric Cooker, Washing Machine etc.) Conclusion Show Video Review / Assessment 1. What are the points to be considered before going for any particular wiring? 2. How do you fulfill the customer‟s requirement? 3. What are the different factors that are to be considered before going for any type of wiring? FAQ 1. How do you specify the wiring system? 2. How many types of loads are there? 3. How can you specify the wiring system? Reference House wiring hand book (ICPCI) Skill Wiring for Staircases, Hotels, Godowns etc. Drawing Room Bed Room Kitchen Bathroom 4 Sq mm Main Distribution Board 4 Sq mm 4 Sq mm 6 Sq mm Main Distribution Board Meter
  • 29.
    23 HOUSE WIRING, CONDUITPIPE WIRING Introduction There are a number of wiring systems that are used in the construction of a building. However, nowadays every customer prefers conduit wiring –especially concealed conduit – because it suits the requirement and expectations of the customer. So we discuss about conduit house wiring system. Teaching and Learning Methodology Lecture, Demo and Practical session Learning Objective After completion of this lesson an aspirant will be able to explain: a. Advantages of conduit wiring b. Precautions to be observed during wiring c. Instructions for conduit pipe wiring d. ISDRTE Rules regarding wiring Preview Uses Open conduit: Godowns, Cinema halls, workshops. Concealed conduit: Domestic, Industrial, Software layouts Advantages of conduit pipe wiring  It has good mechanical strength  It is almost all fire proof. It is fire proof  It is fairly water proof  Mechanical thrust and pressure does not affect the wiring  It is fire proof even when short circuit occurs  The defective wires can be easily replaced  Finding the fault is easier  We can run additional wires whenever Necessary Dis-advantages  It is expensive  Its installation requires skilled and experienced persons Precautions:  The earth wire should be run within conduit  The water or gas should be away from the conduits  The conduit pipes should be cut properly  The conduits ends should not be sharp in order to not tear the insulation of the wires  Guide wire or house wiring spring should be used while wiring  Proper gauge of conduit pipes grip fittings must be used  Conduits must be run according to the circuitry planning ISI Rules Indian Standard Instructions rules regarding various wiring systems are as follows:  Ensure maximum eight loads in a circuit  The switch, MCB / Fuse should always be installed on the phase line  All main switches should be covered with an iron sheet or insulating material sheet  Every thicker pin of socket must be connected with earth wire  The three phase power should be marked in Red, Yellow and Blue  Danger caution board should be hung near main switches that are above 250 Volts  A ceiling fan should be installed at a height of 2.7 to 3.18 m, from the floor  Ensure independent circuits for each room  The power loads and lighting loads should be distributed and connected separately
  • 30.
    24  The mainswitch board and lighting switch boards should be connected at a height of 1.5 m from the ground  The wires used must be of higher cross sectional area to ensure smooth flow of current  40% of the conduit must be empty while running the cables Check list for electrical wiring  Number of points in each room as per the drawing and requirement  Location of the points  Height of the boards from the floor  Quality and specifications of the material being used  Sizes of the boards  Internal connection of main boards and phase switch  Codes and sizes of wires used  Earthing connection  Mains for correct voltage etc. Review 1. What are the factors to be considered before the wiring? 2. Write the different ISI rules related to the house wiring? FAQ 1. At what height (from the floor) should the ceiling fan be fixed? 2. List down the components of the check list for the electrical wiring? Reference Basic electrical engineering by Gupta Skill Surface conduit, concealed conduit DIFFERENT CONDUCTORS USED FOR HOUSE WIRING SYSTEM Introduction The conductor of a cable is like the heart of the human body. The function of the conductor is to carry current, like the heart circulates blood in the body. If the blood circulation is irregular and improper, it may cause various diseases in the body. Similarly if the conductor (copper) is not good, due to reasons like impurity of copper or improper bunching, the current carrying capacity of the conductor will reduce. So we need to use good conductors. Objective After completion of this lesson an aspirant will be able to explain the following: a. Classifications of conductors b. Latest trends in house wiring cables c. Selection of cables and their criteria d. Abbreviations used Teaching and learning Methodology Lecture, Presentation (PPT), Demo and Practical session Preview
  • 31.
    25 Types of wiresused in domestic and industrial wiring are classified as under: According to the core  Single core wire  Two core wire  Three core wire  Four core wire According to insulation (Stand wires)  VIR wire  CTS or TRS wires  PVC wires  FRLC  HFFR  Weather proof wires  Enameled wire  Fire resisting etc. According to the metal  Bare Copper  ACSR Conductor  Fuse wire  Nichrome wires Latest trends to meet present scenario Looking back in history, we come across many accidents like the incident of “Upahar Cinema Hall” (Delhi) which took lives of 175 people due to breathlessness (suffocation) caused because of fire and dense black smoke. The victims could neither see nor be seen by others and thus could not be rescued in time. Fire hazard cables: Keeping the above draw backs in mind we have latest trends in cables such as  FRLC  HFFR  FIREX etc. The main criteria for selection of Cables  Voltage grade for house wiring  1100 V, 1.1 KV grade  Current rating of cables  Voltage drop in cables on current flow  Short circuit withstanding capacity  Derating or safety load etc.  Avoid using obsolete British standard cables such as 1 / 18, 3 / 20 etc.  ISI recommends the use of metric system such as, 1.5 sq mm, 2.5 sq mm, 4 sq mm, 6 sq mm, 10 sq mm Characteristic Normal PVC FRLS PVC Oxygen Index 23 29 Temp. Index 160°C 250°C Acid Gas 40% by Wt 20% by Wt Smoke Density >80% < 60%
  • 32.
    26  Flow colorcodes for wiring (as shown in the picture) o Green – Earthing o Black – Neutral o Red, Yellow, Blue – Phases Abbreviations CTS : Cab Tire Sheathed VIR : Vulcanized Indian Rubber PVC : Poly Vinyl Chloride ETP : Electrolytic Tough Pitch FRLS: Fire Retardant Low Smoke HFFR : Halogen Free Flame Retardant Conclusion There is a need to give examples of many case studies, conventional cables and fire retardant cables to the aspirants. Technicians should recognize the quality of a conductor by seeing it. Review a. How do you classify the cables according to insulation? b. Which are the new cables available in the market used to avoid electric shocks? c. What are the criteria to select a cable? FAQ Write the full forms 1. CTS, VIR, PVC, ETP? 2. FRLS, HFFR? Reference General Information Related Skill  Wires and joints  Routing diagram of single and three phase systems  Laying of conduits on slab  Chipping, laying of conduits and wiring at live sites
  • 33.
    27 CHAPTER IX: ELECTRICITY Sources,Effects, Uses HISTORY AND BASICS OF ELECTRICITY Introduction Although man has been aware of electricity for several centuries, a proper scientific understanding of it began only in the 18th century. In this session, we will learn about the history of electricity and its basics. Aim To understand the history and basic of electricity Objectives After completion of this class the aspirant should be able to understand the following:  History of electricity  Sources of energy  Law of conservation  Definition of electricity History of Electricity  Around 600 BC,Thales, a Greek philosopher, discovered frictional electricity.  In 1600 AD, William Gilbert, an English physicist, coined the word „electrical‟ (Latin word derived from the Greek word electron.  In 1646, Sir Thomas Brown, an English writer, modified the term to „electricity‟.  In 1800, Alessandro Volta, an Italian scientist, discovered a chemical form of producing electricity.  In 1831, Dr Michel Faraday, an English scientist (also known as the „father of electricity‟), discovered dynamic electricity with electromagnetic Induction. He is also called as the ' father of the electricity.' The Law of Conservation of Energy The Law of Conservation of Energy states that energy cannot be created or destroyed; it can only be changed from one form to another. Sources of Electrical Energy Water, Sun, Coal, Fuels, Nuclear, Wind Review  Who invented electricity and chemical electricity?  What is the source of electrical energy?  Define the law of conservation.  What is electricity?  Who is regarded as the father of electricity?  When was dynamic electricity invented? Reference Basic Electrical Engineering by M L Anwani
  • 34.
    28 PRINCIPLES OF ELECTRICITY Introduction Electricityhas become an integral part of our lives. It is essential for lighting, power, air conditioning, refrigeration and a host of other applications. Life without electricity is almost unimaginable. We must therefore have a fair knowledge of the principles of electricity. Aim To introduce the principles of electricity Teaching and learning material Lecture, charts and role play Objectives After completing this class, you should know the following:  What is electricity?  Current, voltage, resistance and units.  Ohm‟s law and the relationship between current, voltage and resistance.  Types of electricity. What is electricity? Electricity is an invisible and untouchable form of energy. But it can felt through its effects. The components of electricity are current, voltage and resistance. Current Current is defined as the free flow of electrons through a conductor, which is measured by an Ammeter, measuring unit is Amps and letter represented by I. Voltage Voltage is an electrical pressure required to drive free flow of electrons through a conductor. It is measured by a voltmeter; measuring unit is volts and letter represented by VorE. Resistance Resistance is the property of a material which opposes free flow of electrons through it. It is measured by an ohmmeter; measuring unit is ohms and letter represented by R. Ohm’s law The Ohm‟s Law was propounded by George Simon Ohm, which defines the relationship between current (i), power (p), voltage (v) and resistance (r) I = v / r - 1 r = v / i - 2 v = i x r - 3 Ohm‟s Law states that, in any closed electrical circuit the current is directly proportional to voltage applied and universally proportional to the resistance of the circuit, temperature and other physical conditions being constant. Review  Define current, voltage and resistance.  What is Ohm's Law?  What is use of Ohm's Law?  Name the different units used in electricity. Reference Basic Electrical Engineering by ML Anwani
  • 35.
    29 EFFECTS OF ELECTRICCURRENT Introduction As we discussed earlier, electricity is an invisible form of energy that can be perceived only through its effects. Whenever current flows through a conductor, it is actually electrons flowing from one place to another. It is not possible to see the electrons or current flow. So it is essential to know about the effects of electric current. Aim To gain an understanding of the effects of electric current Objectives At the end of this lesson you should be able to:  Understand the effects of the electricity.  Explain each effect  Do experiments and demonstrate each activity. Effects of Electricity  Physical effect: The human body is a good conductor of electricity. So when we touch an object through which current is flowing, we get a shock. Severe shock may even lead to death (examples through case studies, activity, etc.)  Heating effect: Whenever current passes through any conductor, heat is produced in that conductor. Such effect is used in a heater, press, lamps, soldering iron, etc. (activity based experiment)  Magnetic effect: This effect is seen in fans, meters, calling bells, etc. (demonstrate a calling bell)  Chemical effect: When current passes through an electrolyte, a chemical reaction takes place. Battery charging and electroplating are good examples.  X-ray effect: When high frequency is passed through a vacuum tube, a special type of high-penetration rays come out, which cannot be seen. They are called x rays; they are used to take images of the insides of our body to diagnose diseases and determine treatment. Review  What are the effects of electric current? Explain each one of them.  How are x-rays produced? What do they do? Reference Basic Electrical Engineering by ML Anwani
  • 36.
    30 CHAPTER X: AC/ DC / POLYPHASE Basics, Differences, Connections, Comparisons, Advantages SINGLE PHASE INDUCTION MOTORS Introduction The construction of the single phase motor is similar to the poly phase induction motor with an exception that the stator has a single winding. So the stator field produced is only alternating instead of starting like in a poly phase system. That is why single phase motor is not self starting. Aim To facilitate knowledge / skills transfer related to single motor Teaching and Learning Methodology Lecture, demo and role play Learning Objective After completion of this session the aspirant shall be able to know: a. Classification of single phase motors b. Construction details of each motor c. Characteristics etc. Preview Classification According to the starting of AC devices, single phase can be classified as following: 1. Split phase motor: a. Plant split single phase motor b. Capacitor start induction runs motor c. Capacitor start, capacitor run d. Permanent capacitor motor e. Shaded pole motor 2. Repulsion motors: a. Plant repulsion b. Repulsion start induction runs motor c. Repulsion induction motor 3. Universal motors: Characteristics of single phase motor: 1. Starting current is high 2. Starting torque is low which increases with load 3. Constant speed but slightly falls with increase in load 4. Power factor is low 5. Maintenance cost is high Split phase single phase motors are used for lathe machines, drill machines etc.
  • 37.
    31 Capacitor motors Capacitor motorsare used for Refrigerants, Compressors, Cloth washing machines, Printing press, Drilling machines, Lathe machines etc. Parts of capacitor motors As shown in the picture (on the right), there are five parts. Those are: 1. Rotor i.e. moving part 2. Stator i.e. static part 3. End covers 4. Centrifugal switch fitted inside 5. Capacitor which is connected in series with the starting winding Review 1. Name the different types of single phase motors? 2. What are the different parts of capacitor motors? 3. Explain different characteristics of AC phase motors? FAQ Which voltage of single phase motor? Reference Basic electrical engineering by Mittal Mehta, M.L.Anwani, Gupta etc.
  • 38.
    32 CHAPTER XI: GENERATORSAND MOTORS Principles, Parts, Uses, Functioning, Starters, General Maintenance AC MOTORS Introduction The electric motors are the most common appliances / gadgets used in a day. In addition to the other fields, Electricity also plays a vital role in Agriculture. AC motors is a very wide class of motors, which includes single phase, poly phase, universal, servo, Induction synchronous motor etc. Aim To impart the knowledge and skills related to AC motors. Teaching and Learning Methodology Lecture, Demo and site visit. Objective Upon completion of this lesson the aspirant would be able to a. Define and explain the working principle of AC motors b. Explain the construction details of AC motors / classification c. Practice maintenance, troubleshooting and installation Preview 1. What is an AC motor? A motor is a device which transforms the electrical energy into mechanical energy. AC motors are used worldwide in many residential, commercial, industrial and utility applications. The stator of an AC motor is similar to the stator of a rotation field type of alternator. 2. Working principal of induction motors AC is supplied to the rotor, which produces a rotating magnetic field. This field causes the rotor of the motor to rotate. As the rotor rotates it cuts the magnetic field produced by the stator and an EMF is induced in it. Principle When a short circuit conductor is placed in a rotating magnetic field, the conductor tends to move. 3. Classification of AC motors AC/DC According to the working principle a. Synchronous Motor i. Plain synchronous Motor ii. Auto Synchronous Motor b. Asynchronous Motors I. Three phase induction motors i. Squirrel cage induction motor ii. Slip ring induction motor iii. Commutator motor II. Single phase induction motors i. Split phase induction motor ii. Capacitor induction motor iii. Universal induction motor iv. Shaded pole induction motor
  • 39.
    33 v. Repulsion inductionmotor According to the phase a. Poly phase motor b. Single phase motor According to the speed a. Constant speed motor b. Variable speed motor c. Adjustable speed motor According to the construction a. Enclosed type motor b. Semi enclosed type motor c. Open type motors d. Reverted type motor e. Ventilated type motor Construction Construction of 3 phase, 1 phase motor parts are as follows: a. Stator b. Rotor c. End cover d. Bearing e. Fan Common Troubles and Repairs The symptoms encountered and their possible outcomes, in defected 3 phase motors are as listed below. 1. If motor fails to start The troubles may be:  Burned out fuse  Worn out bearings  Overload  Open Phase  Shortened coil  Loose rotor bars  Wrong general connection  Frozen Bearing  Grounded winding  Defective controllers 2. If the motor runs slowly The troubles may be  Shortened coils / groups  Reversed coils / group  Worn out bearings  Overload  Wrong connection, Reversed phase  Loose rotor bars Installation Electrical machines and apparatus should always be installed where:  They can get adequate ventilation and clean dry air  They should be accessible for full inspection and repairs  The machine is erected on solid and vibration free foundations  The motor is anchored by means of foundation studs  The machines is always carefully aligned  The slide rails house the screws in opposite directions
  • 40.
    34 Note: A sitevisit, practical session on dismantling and constructing etc. Latest trends Energy efficient motors Conclusion An electrician has to do the erection work also. At most of the places the motor should be kept 8 or 10 cm above the floor. Electricians must be up-to-date with the latest trends in the market. Review 1. What is an AC motor and how does it work? 2. How many types of AC motors are there? 3. Name the single phase motors? FAQ 1. Name the parts of an AC motor? 2. What are the common troubles that arise? Reference AC Machines - Mehta
  • 41.
    35 DC GENERATORS Introduction Energy isthe basic necessity for the economic development of a country. There was no power generating system in the olden days. Later a new generation of power was started in the form of DC generators then they were modified to have increased efficiency and called as AC generators or alternators. Aim To make the aspirants familiar with a DC generator Teaching Learning Methodology Lecture, Demonstration and Site visit Learning Objective After completion of this lesson an aspirant would be able to: a. Define a generator and explain its working principle. b. Explain construction details of DC Generators. c. Classify DC generator. Preview DC Generator DC generator is a machine which converts the mechanical energy into DC electrical energy. Working Principle According to Dr. Faraday‟s Law of Electromagnetic Induction, the conductor (armature) is rotated in the magnetic field system and EMF is induced in that conductor, which is collected from the commutator fitted on the shaft of armature. DC generator can work as a DC motor, when electrical power is fed to the machine. Construction Details The different parts of a DC generator are as under: a. Yoke or body b. Pole core and pole shoe c. Armature d. Commutator e. Brushes and bearing f. Field coils Note: Explain about each part in detail Types of DC Generators DC generators are classified according to their field. They are of two types. 1. Self excited generator 2. Separately excited generator. 1. Self excited Generators are those, whose field magnets are excited by themselves. There are again three types of self excited generators. a. Serious wound Generator b. Shunt wound Generator c. Compound wound Generator Compound WOUND generators are further classified into two ways: i. Short shunt compound wound generator ii. Long shunt compound wound generator
  • 42.
    36 Conclusion DC generators arenot economical and AC generator are replaced them in present days. Review / Assessment 1. What is a DC generator and how does it work? 2. Name the parts of a DC generator? 3. What are different types of a DC generator? FAQ: 1. Function of commutator 2. Function of carbon brushes Reference Basic Electrical Engineering by Mittal & Mehta. Practical Site visit AC MOTOR STARTERS Introduction If an induction motor is directly connected to the 3 phase supply, it would draw a full load of current. However, since the motor is not running this heavy flow of current may damage the motor windings as well as the line. In order to decrease the staring current a starting device is used with the motor, which is known as starter. The starter reduces the starting voltage and hence the starting current. Aim To impart knowledge and skills related to the starters. Teaching Learning Methodology Theory, Demonstration and Practical Session Learning Objective At the end of this class the aspirant would be able to: a. Define the starter b. Explain about different starters used for different purposes c. Know about functions of protective device d. Explain construction and functioning of each starter e. Draw the circuit diagrams of each starter Preview Starter Starter is a device used to start the AC motors, safely and to minimize the starting current to protect the motor from load and high voltage. Types of starters The different starters used for the purpose are as follows: 1. Direct online starter (DOL) 2. Star Delta starter i. Manual semi delta starter
  • 43.
    37 ii. Semi Automaticdelta starter iii. Fully automatic delta starter 3. Auto: Transformer type starter 1. Direct Online (DOL) Starter It is a simple and ordinary starter, suitable for squirrel cage induction motors that have a capacity up to 5 HP. It does not reduce the voltage. It is sufficient to connect the motor from the line ICTP / Main switch / Isolator. The DOL starter has the following advantages: a. The motor can be switched on and off quickly. b. It cuts the motor from the line one over loads. c. It prevents the motor from burning on single phase.  Mainly DOL starters consist of contact system thermal relay units and a solenoid coils.  The contact system consists of silver tipped contacts, which provides a quick on – off system.  Thermal relay bimetallic elements protect the motor from over load.  The solenoid coil or no–volt coil is connected across the two phases. (Phase and neutral in case of single phase)  On pressing the start button the solenoid coil becomes magnetized and it attracts the iron, plunger, which closes all the contact points.  In this way L1, L2 and L3 are connected to the motor terminals M1, M2 and M3 and the motor starts running, as shown in the picture above. Push buttons are used in place of the handles. The green push button starts the motor, while the red push button switches off the motor. A latch fitted near the red push button can be adjusted over it, so that motor may not be started. Protective Devices No–Volt Coil (NVC) and Over Load coil Relay (OLR) are provided in a start delta starter as protective devices. No–Volt Coil (NVC) [Ref Figure given below] It is an electromagnetic coil made of fine copper wire. The NVC is connected to B2 and A2 terminals. These terminals get supply from L1 to L3 respectively in the run position. If the supply fails, the motor becomes over loaded, then the NVC will be demagnetized and will release the handle, thus the motor will be switched off. Over–Load Relay It consists of three bi-metallic strips, which get bent in one direction, above a pre-set temperature. The bending of these strips disconnects the NVC, which will leave the hands of
  • 44.
    38 the starter tooff position. Each strip is connected in series with a phase line. The leaver of the OLR dial is set in such a position that the tripping will occur at about 25% over load current. Star Delta Starter This starter is fitted in 5 HP to 10 HP motors. In this starter there are two way switches which connect the six ends of the motor once in star and then in delta. It also has OLR, No-volt coil, current adjuster and off switch like the DOL starter as shown in the picture. Auto-Transformer Starter A starter of this type is used in up to 25 HP motors. This type of starter has an auto – transformer from which many tapings are taken out which give different voltages by which a big motor can be supplied with low voltage, while in the Star Delta Starter only 13 times the full voltage can be given to the motor. The torque also varies with the voltage. It also has OLR, NVC and off switch as per the diagram. Some other starters are also available like resistance type starter, auto starter etc. Common faults that occur  The starter of a slip ring motor has short circuit defect  The starter of a slip ring motor is earthed  The contact points of the starters remain in open circuit  The No–volt coil is not functioning  The Over Load Relay coil is defective  The starter connection is wrong Latest trends Automatic starters Review / Summary a. What is a starter and why is it necessary? b. How many types of stares are there? c. What are the common faults occurs in starters? FAQ a. NOC b. OLR c. DOL d. Star delta Skill Connecting DOL, Star delta starters to the motor and preparing a panel board.
  • 45.
    39 CHAPTER XII: TRANSFORMER Principle,Types, Parts, Cooling Methods, Maintenance Introduction Now a days AC system, Specially 3 phase (poly phase) system is most commonly adopted for generation, transmission and distribution, because it is economical and efficient. In India all generating stations and alternators are practically producing 11 KV/ 21 KV. Using the AC system, such power can be stepped up, transmitted and distributed to reach the consumers‟ point, keeping low cost and reduced size of conductor in mind. A transformer is a device which conveys power from the generating station to the consumers‟ point. Aim To teach about transformers Teaching and Learning Methodology Lecture, Demonstration Learning Objective After completion of this lesson the aspirant would be able to: a. Define and explain working principle of transformers b. Classify the different types of transformers c. Name the parts and draw the 3 phase transformers Preview Transformer The transformer may be defined as a static piece of electrical apparatus which converts electrical power from one circuit to another at the same frequency while changing the corresponding values of current and voltage. Working Principle The transformer works on the principle of Mutual Induction. Classification of Transformers 1. According to the magnetic core a. Core type b. Shell type c. Berry type 2. According to the voltage a. Step up transformers b. Step down transformers 3. According to the phases / winding a. Single phase transformer b. Three phase transformer 4. According to the power / usage a. Lighting / distribution transformer b. Power transformer
  • 46.
    40 5. According cooling a.Self cooled b. Air force cooled c. Oil self cooled d. Forcibly oil cooled 6. According to the location a. Indoor transformer b. Outdoor transformer 7. According to the output: a. Auto transformer b. Instrument transformer Protection devices a. Conservator b. Breather c. Temp Gauge d. Explosion vent e. Pipes etc. Review / Summary a. Define „Transformer‟ b. Classification of a Transformer c. Discuss the appropriate site for Installation of a Transformer d. Name different protection devices used in a Transformer FAQ  Function of Breather  Primary Coil  Secondary coil Reference Basic Electrical Engineering by Gupta
  • 47.
    41 CHAPTER XII: UPS Basics,Connections, Maintenance LEARNING OBJECTIVE To know about the UPS, types, its functions and maintenance of batteries. UPS (UNINTERRUPTIBLE POWER SUPPLY) It is an electrical apparatus, provides energy power to a load, where input power source fails. Typically it is used to protect computers, data centers, telecommunication equipment or other electrical equipment where an unexpected power disturbance could cause damage, fatalities, serious business disruption and/or data loss. FUNCTION OF UPS Primary role of UPS is to provide short term power, when the input power source fails. However, most UPS units are also capable in addressing in varying degrees of correcting common utility power problems like: 1. Power Failure: 2. Surge : Momentary increase in main voltage 3. Sag : Decrease in input voltage 4. Spike : Brief high in voltage excursion 5. Noise : Oscillation 6. Instability : Temporary change in mains frequency 7. Harmonic 8. Distortion : Departure from the ideal sinusoidal waveform expected on the line TYPES OF UPS Since UPS address a no. of problems so divided into categories based on which they address the problem; · ON-LINE UPS · LINE-INTERACTIVE UPS · STANDBY UPS (OFF-LINE) Online UPS Line interactive UPS Standby UPS
  • 48.
    42 BATTERIES AND ITSMAINTENANCE Batteries are of various kinds may provide power for minutes, hours or days depending upon the electrical design. Usually it is flooded with lead-acid battery stalled in groups, several batteries are wined together in a series circuit forming o group providing DC electric power at 12V, 24V, 48V OR 60V (may be higher) , there are two or more group of batteries which are connected in parallel circuit. In a large scale set-up a separate battery room is there to house the batteries. Proper placement and maintenance of batteries are very important for shelf life of battery. Typical batteries may give hydrogen gas (H) so ventilation is critical otherwise it may cause explosion. There must be proper temperature maintenance because at high temperature life span of battery gets reduced and at low temperature energy storage capacity is reduced.
  • 49.
    43 NAME OF EXPERIMENT Measurementof wire sizes LEARNING OBJECTIVE At the end of the exercise, the aspirant should be able to:  Skin the insulation of a cable  Measure the size of a wire using a wire gauge – in gauge no.  Measure the size of a wire using a micrometer CIRCUIT DIAGRAM TOOLS REQUIRED  Standard wire gauges 0-36 SWG - 1 no.  Electrician‟s knife - 1 No.  Combination‟s pliers - 1 No.  Manual wire stripper - 1 No.  Micrometer 0- .25 mm - 1 No. MATERIALS REQUIRED Material Specification Quantity Schneider products Cable pieces Cotton cloth 30 cm long each of size – 20, 18 , 16, 7/22 , 14/36 ,7/18 30x30cm Each one 2 pieces 2 No. PROCEDURE AND OBSERVATION TASK 1: Measuring the wire sizes by SWG 1. Skin the insulation of the cable 2. Clean the surface of the wire with a cotton cloth , remove insulation particles and any adhesive coating over the conductor surfaces 3. Straighten the end of the conductor to be measured 4. Insert the conductor in the slot of the wire gauge and determine the close fit slot 5. Read the marking at the slot, it gives the wire size in SWG. The other side will give the diameter of the wire in mm
  • 50.
    44 OBSERVATION 1. Record themeasured size in Table 1 TABLE 1 Sl.No Size SWG Diameter in mm 2. Repeat the measurements for all the cables included in material list SAFETY PRECAUTIONS Exercise care to prevent nicking and do not use any hand tool directly on the conductor for straightening.
  • 51.
    45 NAME OF THEEXPERIMENT Prepare terminations - Skinning Cable ends LEARNING OBJECTIVE At the end of the exercise the aspirant will be able to  Identify the cutting tools such as an electrician‟s knife  Sharpen the electrician‟s knife , Combination‟s pliers  Skin (cut and remove) the insulation of cables using knife manual stripper- wire stripper with auto ejection CIRCUIT DIAGRAM TOOLS / INSTRUMENT REQUIRED  Electrician‟s knife 80 mm blades - 1No.  Wire stripper, manual 200 mm - 1 no.  Wire stripper auto – eject 150 mm - 1No.  Combination pliers 150 or 200 mm - 1 No.  Steel rule 300 mm - 1No.  Diagonal cutter or side cutting Pliers 150 mm - 1 No.
  • 52.
    46 MATERIALS REQUIRED Assorted smallsizes pieces required for practice PROCEDURE AND OBSERVATION TASK 1: Skinning cable insulation using knife 1. Mark the length of the 1.5 sq mm cable at 400 mm from its end 2. Cut the cable using combination pliers at the mark. 3. Mark the amount of insulation to be skinned from either end. 4. Check the sharpness of the knife blade and re- sharpen if necessary 5. Remove the insulation of the cable for about 10 mm at its ends using a knife. Keep the knife blade at an angle less than 45 to the cable. 6. Check there is no nicking over the conductor and cable is not shaved off. 7. Clean the surface of the bare conductor. 8. Cut the cable at the 12 mm from either end using combination pliers. 9. Repeat step No. 5 to 8, until the cable length is 350 mm. 10. Mark the insulation to be removed as in Fig 3 and repeat step No. 5 and 6. 11. Repeat the skinning of cable insulation of 2.5 sq mm cable, 14/0.2 mm, 48/0.2 mm, 23/0.2 mm, 80/0.2 mm and 128/0.2 mm flexible cables. 12. The length of the finished skinned cable should be of 300, 500, 600, 800, 1000 mm in each size. SAFETY PRECAUTIONS  While using this tool, make sure it is correctly adjusted before trying to strip the insulation from the cable without damaging the conductor and never use this tool to cut metallic conductor. Material Required Specification Quantity Schneider electric Products Aluminum cable of Following sizes Single strand cable 1/1.4 , 1.5 sq mm 3M - Single strand aluminum cable 1/1.8 ,2.5 sq mm 3M - Flexible cable Copper conductor 14/0.2 mm 23/0.2 mm 48/0.2 mm 80/0.2 mm 128/0.2 mm 3M 3M 3M 3M 3M - - - - -
  • 53.
    47 NAME OF THEEXPERIMENT Making of simple twist joints LEARNING OBJECTIVE After completion of this exercise the aspirant should be able to  Mark the length of insulation to be removed  Skin the insulation  Prepare a straight twist joint  Prepare a rat –tail joint CIRCUIT DIAGRAM Fig 1 Fig 2 Fig 3 Fig 4 TOOLS /INSTRUMENTS REQUIREMENTS  Electrician‟s knife with two folding steel blades 75 and 100 mm - 1 No.  Steel rule 300 mm, stainless steel with graduations on either edge Cm/ mm and inches - 1 No.  Diagonal cutting pliers 150 mm with 660V grade insulated handle Suitable for cutting hard wires - 1 No.  Combination pliers 200 mm with 660 volts grade insulated handles With pipe grip, side cutter and two joint cutters - 1 No. MATERIALS REQUIRED Material required Specification Quantity Schneider Electric Product Insulated Copper cable 1/1.12 2M Insulated Aluminum cable 1/1.40 2M Cotton cloth 30 cm sq 1No. Paper “00” smooth 1 sheet
  • 54.
    48 PROCEDURE AND OBSERVATIONS 1.Collect two pieces of 1/1, 12PVC copper cable of 0.5 m length. 2. Straighten the cables. 3. Mark 80 mm length on one end of each piece of the cable. 4. Use the knife at an angle of 20 as shown in Fig 2, and remove the insulation from each conductor for a distance of 80 mm. 5. Clean the ends with the help of cotton cloth. 6. Place the conductors together, about 50 mm from the ends. 7. Twist them tightly around each other in opposite directions. 8. Cut off the excess length of the conductor with side cutters. 9. Press the sharp edge of the conductor end and smooth it. 10. Cut off the joint after leaving 30 mm cable from the joint. SAFETY PRECAUTIONS  Pliers can be used to just grip the crossed conductors and each side to contain about 6 turns. Each turn of a conductor should fit closely to the adjacent turn.
  • 55.
    49 NAME OF THEEXPERIMENT Making of tee joint in stranded conductors LEARNING OBJECTIVE At the end of this exercise the aspirant will be able to  Prepare a Tee joint in the given multi stranded conductors CIRCUIT DIAGRAM Fig 1 Fig 2 Fig 5 Fig 3 Fig 6 Fig 4 TOOLS/INSTRUMENTS REQUIREMENTS  Electrician‟s knife 75 and 100mm - 1 No.  Steel rule 300 mm - 1 no.  Diagonal cutting pliers 150 mm - 1 No.  Combination pliers 200 mm - 1No.  Wooden mallet 75 mm dia. - 1No.
  • 56.
    50 MATERIALS REQUIRED Material RequiredSpecification Quantity Schneider Electrical Product PVC Insulated copper Cable of 7/0.91,660V 0.5 M 2 PIECES Cotton cloth 30 X 30 mm 1 PIECE PVC Insulated aluminum cable 19/1.12 or 19/1.63 0.5M Sand paper “ 00 ”GRADE 25 sq cm PROCEDURE AND OBSERVATION 1. Collect two pieces of PVC insulated stranded copper cable 7/0.91.Indicate one piece as „through cable‟ and the other one as „tap cable‟. 2. Mark the point of tap in the „through cable‟ and mark 60mm on either side of the tap point for the insulation to be removed. 3. Remove 60mm insulation on either side of the „through cable‟ from the point of tap. 4. Remove the insulation for 180mm at the end of the „tap cable‟. 5. Open the strands of the „tap cable‟ and clean them .Use smooth‟00‟ sand paper, if necessary. 6. Re –twist the strands in the original direction upto 50 mm from insulation and make a binding on the twisted part of the „tap cable‟. 7. Untwist the „through cable‟ to provide an opening at the point of tap. 8. Insert the center strand of the „tap cable‟ in the opening of the „through cable‟. 9. Wrap 3 strands of the „tap cable‟ around the „through cable‟ on either side of the tap point. 10. Wrap the strands up to 50mm to leave a10mm between insulation and shoulders and trim the excess length of strands. 11. Remove the binding from the tap cable, wrap center strand of the „tap cable‟ around „through cable‟ and wrap it in the place of the binding. 12. Round up the ends with the combination pliers mallet to avoid sharp edges of the strands. 13. Collect two pieces of PVC stranded aluminum cable 19/1.12, or 19/1.63, 500mm long and repeat step 2 to12. SAFETY PRECAUTIONS  Do not nick or shave the conductor while removing insulation.
  • 57.
    51 NAME OF THEEXPERIMENT Solder copper conductor joints LEARNING OBJECTIVE At the end of this lesson the aspirant should be able to  Solder copper conductor joints using a soldering iron and rosin-cored solder. CIRCUIT DIAGRAM TOOLS/INSTRUMENTS  Combination pliers - 1No.  Electric soldering iron 60W, 250V, 50Hz - 1 No.  File flat, bastard 150 mm - 1No. MATERIALS REQUIRED Material required Specification Quantity Schneider Electrical product Soldering iron with Cleaning pad 1No. Wire Brush 1No. Cotton cloth 30x30 cm 1No. Osin-cored solder 25gm Sand paper “00” GRADE 9Sheet PROCEDURE AND OBSERVATION 1. Select a60W, 230V AC 50Hz soldering iron and ensure that the iron has no physical damage the body is well insulated from the element and is of the correct voltage and power rating. 2. Surface of bit is to be smooth and clean. 3. Connect the soldering iron to the supply and switch it ON
  • 58.
    52 4. When thebit becomes sufficiently hot ,apply a small quantity of rosin-cored solder, and tin the bit 5. Wipe the bit gently on the cleaning pad to remove excess solder. 6. Clean the joint to be soldered with the help of sandpaper “00”grade and wipe the dust. 7. Keep the soldering iron bit on the joint and heat it for soldering. 8. When the joint is heated, keep the rosin-cored solder on the joint and allow it to melt. 9. Melt the solder with the heat of the bit and make sure the solder flows freely and evenly on the joint. 10. Remove the soldering iron; wipe off the excess solder from the surface of the joint by cotton cloth, when it is still hot. 11. Let the joint to cool naturally. Do not blow air for cooling. SAFETY PRECAUTIONS  If the bit is not completely and evenly covered with solder, clean and tin it again.  Never flick excess solder off the bit .The hot solder may cause burn to someone or fall into part of the work ,and cause a short circuit.  A shining solder surface ensures a good soldering .Do not move the joint until the solder solidifies. Do not keep soldering iron on wood/plastic.
  • 59.
    53 NAME OF THEEXPERIMENT Termination of cable ends LEARNING OBJECTIVE At the end of the exercise, the aspirant will be able to  Prepare the cable end for loop termination on screw terminal  Prepare a loop termination CIRCUIT DIAGRAM TOOLS REQUIRED  Steel rule 300mm  Electrician‟s knife  Wire stripper(manual)  Combination pliers 200mm  Screwdriver 100/150mmx4mm  Screwdriver 100mmx2mm  Long round nose pliers 150mm MATERIALS REQUIRED Material required Specification Quantity Schneider Electrical product Aluminum pieces + Copper cable 200 to 300mm As required Single conductor cable 1.5,2.5 sq mm As required Bare copper wire No 10 SWG 300mm Cable multi strand 14.02 mm As required PROCEDURE AND OBSERVATION 1. Take a single conductor cable of 1.5sqm of length 250 to 300mm. 2. Remove the insulation for the required length to make a loop. 3. Grip and turn the conductor with nose pliers. 4. Turn firmly gripped nose pliers to form required loop. 5. Repeat the same procedure for multi stranded wire also. SAFETY PRECAUTION  The loop should go at least about three quarters of the way around the screw and check the inner diameter of the loop with the terminal screw.  Never make the loop so long that the conductor can overlap. Keep the length of the exposed conductor to the minimum not more than 3mm to prevent accidental contact with other wires.
  • 60.
    54 NAME OF THEEXPERIMENT Crimping of cable ends LEARNING OBJECTIVE At the end of the exercise, the aspirant will be able to  Skin the cable end  Select the pressure terminal( compression connector) that suits the wire size and the terminal size  Select the pressure pliers that match the pressure terminal size.  Use the crimping tool to crimp pressure terminal (lug) at the cable end. CIRCUIT DIAGRAM TOOLS REQUIRED  Pressure pliers200mm -01  Electrician‟s knife 100mm -01  Wire stripper (manual) 200mm -01  Combination pliers 200mm -01  Crimping pliers 150/200mm -01  Wire stripper auto-eject 200mm -01  Steel rule 300mm -01  Side cutting pliers 150mm -01  Eyelet closing pliers 200mm with -01 Former for eyelets having inner Diameter of 3, 4, 5, 6, 7mm
  • 61.
    55 MATERIALS REQUIRED Material RequiredSpecification Quantity Schneider Electrical Product Compression connectors Crimping eyelet, Eyehole 6mm(Diameter) 12 Nos. Crimping ferrule 4mm,10mm Long 6 No. Crimping Spade lug 6A 6No. Crimping Spade 10A,16A LUG 6No. Conductor or Pastes - 1 Tube PROCEDURE AND OBSERVATION 1. Collect the cable (fine multi strand copper conductor). 2. Collect the spade connector suitable to the wire thickness and terminal size (6mm diameter) 3. Select the wire stripper blade size to match the wire thickness (auto-eject) or adjust the jaws of the stripper. 4. Strip off a length of insulation that suits the terminal size (spade connector). 5. Twist the strands of the wire lightly in the direction of strands. 6. Select the crimping pliers that match with the terminal size. 7. Clamp the spade connector with the crimping pliers 8. Insert the wire far enough in the compression connector. 9. Apply light pressure to create a light impression on the compression connector. 10. Check whether the press is located in the middle of the band of compression connector and if necessary, make final adjustment. 11. Apply sufficient pressure in the handle to press the compression connector fully. 12. Check whether the prepared compression/crimping joint are firm by pulling the cable and compression connector. 13. Repeat the crimping of compression in connectors various sizes of copper and aluminum conductors of different lengths. SAFETY PRECAUTIONS  Be sure not to cut or damage the wire core  Don not clamp the insulation in the terminal  Strands must not stick out of the connector  Don not strip off too much insulation
  • 62.
    56 NAME OF THEEXPERIMENT Identify the phase and neutral in single phase AC supply LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Test and identify a phase wire and neutral with the help of a test lamp  Test and identify a phase wire and neutral with the help of a voltmeter  Test and identify a phase wire and neutral with the help of a neon tester  Identify phase and neutral with the help of colour coding CIRCUIT DIAGRAM MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 Test lamp 230V / 250V 40W/60W/100W 1 each 2 Volt Meter 0-300V MI 1 no. 3 Neon Tester 500V 1 no. 4 Connecting leads 2mtr PROCEDURE AND OBSERVATION Task 1: Test lamp method 1. Connect the test lamp 230V/250V, 40/60/100W with supply for checking its function 2. Connect one lead of the test lamp to the earth point 3. Touch the other lead of the test lamp to any one of the supply terminals
  • 63.
    57 4. Does thetest lamp glow? If yes, mark the terminal as PHASE. Go to step 7 5. If the test lamp does not glow, touch the lead to the other supply terminal. Observe the lamp condition. 6. Mark this terminal as PHASE (L), if the lamp glows. 7. Remove the lead connected to earth. Touch both leads of the test lamp across the supply terminals. 8. Mark the unmarked terminal as neutral (N), if the lamp is glowing. Task 2: Voltmeter method 1. Connect the voltmeter (300V, MI) across the supply mains and check for indication of the supply voltage. 2. Connect one lead of the voltmeter to the EARTH POINT. 3. Connect a testing prod to the other terminal of the voltmeter. 4. Open the cover of the isolating switch fuse unit (ICDP) and touch with the other lead of the voltmeter to any one of the supply terminals 5. Observe the voltmeter; if it reads the supply volt, mark the terminal with the testing lead. Observe voltmeter reading. 6. If The Voltmeter is not indicating /reading, touch the other supply terminal with the testing lead. Observe voltmeter reading. 7. Is the voltmeter indicating the supply voltage? If yes, record the value ______ volts. Mark this terminal of supply as PHASE. 8. Remove the lead connected to earth and touch the other supply terminal with it. 9. If the meter reads the supply voltage, mark the unmarked supply terminal as Neutral. Task 3: Neon Tester 1. Check the neon tester for its function. 2. Place the testing end of the neon tester in any one of the socket outlet terminals 3. Touch the other end of the neon tester with your finger. If the neon tester glows that terminal is PHASE. 4. If the neon tester is not glowing, remove the neon tester and touch the other terminal. Observe the neon tester‟s glow condition. 5. If the neon tester is now glowing, mark the terminal as PHASE. SAFETY PRECAUTIONS  If the voltmeter is not reading when touch with either of the terminals and earth, check for AC supply failure  Make sure you are touching the wall or floor well with hand /foot for bright indication of the neon tester  The phase should be connected to the left side terminal of ICDP. The right side terminal is always neutral. (this is the recommended code of practice)
  • 64.
    58 NAME OF THEEXPERIMENT Identify, dismantle, sketch and assemble different electrical accessories LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Identify specified electrical accessories of the following categories used in domestic wiring  Switches  Lamp –holders  Socket outlets  Ceiling roses  Fuse units  Fan regulators  Dismantle the above accessories to identify the holes for mounting, cable entry and connecting terminals  Assemble the accessories  Represent the accessories by standard symbols CIRCUIT DIAGRAM Socket 3pin Single pole switch Fuse cut out Plug top 3pin
  • 65.
    59 Ceiling Rose Pendentholder Fan regulator Batten holder MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 Single pole switch 6A, 250V 2 nos. Yes 2 Socket (3 pin) 6A, 250V 2 nos. Yes 3 Plug top(3pin) 6A, 250V 2 nos. 4 Fuse cut out 6A, 250V 2 nos. 5 Ceiling rose 6A, 250V 2 nos. 6 Pendent holder 6A, 250V 2 nos. 7 Fan regulator 6A, 250V 2 nos. yes 8 Batten holder 6A, 250V 2 nos. 9 Socket – 3pin 16A, 250V 2 nos. Yes 10 Plug top -3pin 16A, 250V 2 nos. yes 11 ICDP switch 16A, 250V 2 nos. 12 DP switch 16A, 250V 2 nos. yes 13 Bell push 6A, 250V 2 nos. 14 Single pole MCB 10A, 250V 2 nos. yes 15 Double pole MCB 16A, 250V 2 nos. yes 16 Three pole MCB 32A, 440V 2 nos. yes 17 Four pole MCB 63A, 440V 2 nos. yes 18 ELCB 32A, 440V 2 nos. yes 19 RLCB 63A, 440V 2 nos. yes 20 Two way switches 6A, 440V 2 nos. yes TOOLS REQUIRED  Screwdriver 150mm with 4mm blade width - 1 no.  Connector screwdriver 100mm - 1 no.  Tray 10x10x4 cm - 1 no.  I.S. books on graphic symbols - 1 set (B.I.S 2032 all parts)
  • 66.
    60 PROCEDURE AND OBSERVATIONS 1.Identify each accessory and write the name in the attached sheets. 2. Write the specification of each accessory by the side. 3. Dismantle the accessory carefully. 4. Compare the actual internal parts of the given accessory with the internal view of each accessory given in the sheets for identification. 5. Fill up the answers in the identification column given against each accessory. 6. Assemble the accessory. 7. Identify the symbols used for the accessory from the related theory or B.I.S books and sketch the symbols in the columns / spaces provided. 8. Show the completed sheets of specifications, identification and symbols to the instructor and get his approval. SAFETY PRECAUTIONS  Most of the specifications can be collected from the markings on the accessory itself. Otherwise try to get them from an approved catalogue or approach the instructor for guidance.  Open only one accessory at a time. Take care of the fixing screws, rings and washers.  Collect the parts in the tray. Metal parts inside the accessory need not be removed.  Different manufacturers design the outline of accessories differently to suit various conditions. However, the electrical contact positions of the accessories remain the same. As such there should not be much difficulty in identifying the accessories.  On the other hand, single way and two way switches as well as two and three plate ceiling roses look alike. A careful look at the rear of the accessory will make the identification process much easier.
  • 67.
    61 NAME OF THEEXPERIMENT Study of Multimeter LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Measure AC/DC voltage  Measure current  Continuity test  Measure resistance CIRCUIT DIAGRAM MATERIAL REQUIRED  Multimeter (1000V for AC and 650V for DC) - 1 each  Torque tester (600A) - 1 no. TOOLS REQUIRED  Cutting pliers - 1 no.  Neon tester - 1 no.  Screwdriver set - 1 no. PROCEDURE AND OBSERVATION Task 1: Measuring AC voltage 1. Take multimeter/clip-on-meter and set the switch to AC position 2. Plug the two leads of the meter to 3. Measure the voltage between phase & neutral, phase & earth and neutral & earth. (if any leakage) Task 2: Continuity Test 1. Set the multimeter switch to position 2. Plug the leads if the meter to
  • 68.
    62 3. Check forcontinuity of a wire, bulb, choke etc. It gives beep sound in case of continuity. 4. Set the meter switch to position 5. Follow step 2 6. Meter shows the resistance of the particular things Task 3: Measuring current 1. Unplug the leads of the meter 2. Set the switch to position 3. Hook the clips/ jaws of the meter to any live wire 4. Meter shows the flow of current SAFETY PRECAUTION 1. Set the meter position and range properly. 2. Do not measure beyond the rated voltage, current etc. 3. Hold / touch the leads properly.
  • 69.
    63 NAME OF THEEXPERIMENT Makin of test board (series and parallel) LEARNING OBJECTIVES  To check the continuity  To check the loupe etc CIRCUIT DIAGRAM Fig. 1: Series circuit Fig. 2: Parallel circuit MATERIALS REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 SP switch 230V / 6 Amps 2 nos. Yes 2 2-pin socket 230V / 6 Amps 1 no. Yes 3 Batten Holder 2 nos. 4 Pin plug Top 230V / 6 Amps 1 no. 5 Wire wire 1.5 sq.mm Single conductor 5 mtr 3 mtr 6 Wooden box 12” x8” 1 no.
  • 70.
    64 TOOLS REQUIRED  Screwdriverset - 1 no.  Cutting pliers - 1 no.  Neon tester - 1 no.  Electrician knife - 1 no.  Wire stripper - 1 no. PROCEDURE AND OBSERVATIONS 1. Fix the switch, socket and holder in a line on the cover of the wood board. 2. Do the wiring as per the circuit diagram. 3. For parallel circuit board, fix the switch & holder in line. 4. Connect the wires as shown in circuit diagram. 5. Fix / connect 2 single conductor wires as testing leads to 2 pin plug top. 6. To check any continuity plug the 2 pin plug (testing leads) and hold the other bare ends properly. 7. Switch ON the power supply 8. For testing purpose short the 2 ends of testing leads 9. Now you can check any continuity of motors, choke, wire etc. SAFETY PRECAUTION 1. Connect the phase wire through switch only. 2. After continuity check, switch off power supply & unplug the leads. 3. Be careful when you are testing the components.
  • 71.
    65 NAME OF THEEXPERIMENT Assemble and install a fluorescent lamp LEARNING OBJECTIVES At the end of this exercise, the aspirant will be able to  Form a circuit for fluorescent lamps of a given size for domestic purposes.  Connect a fluorescent lamp with accessories and install it. CIRCUIT DIAGRAM MATERIALS REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 Tube light fitting set 1200mm 1 2 Starter choke 230V 40W 1 each 3 Fluorescent lamp 1200mm/40W/230V 1 no. 4 Flexible wire Twin twisted 14/.02 copper 4 mtr TOOLS REQUIRED  Test lamp 40W, 240V - 1 no.  Nose pliers 150mm - 1 no.  Connector screwdriver 100mm - 1 no.  Electrician‟s knife - 1 no.  Cutting pliers 150mm - 1 no.
  • 72.
    66 PROCEDURE AND OBSERVATION 1.Check the choke for its short and open with a test lamp as shown in fig and record the results. 2. Check the starter with a series test lamp as shown in Fig. Observe the flickering of the lamp which indicates good condition of the starter. 3. Assemble the following fluorescent tube accessories in the fitting base. Refer to the sketch. 4. Connect the accessories as shown in Fig. and install the tested starter. 5. Test the filament on both sides of the fluorescent tube for its continuity as shown. Discard the fluorescent tube with open or fused filament in either side. 6. Fix the bulb in the holder  Firstly, you have to make sure that the slot in the inner parts of the holder is turned to the proper position.  Then insert both the ends (pins) into the holder of the fittings on either side of the tube. Push the socket pins all the way into the fittings until you feel that you can turn the tube in the sockets. 7. Test the tube light assembly for its working. SAFETY PRECAUTIONS  Be careful not to bend the pins at either end of the tube.  Check the supply at the ceiling rose. Switch off the supply before making any connection.
  • 73.
    67 NAME OF THEEXPERIMENT Assemble, connect and install a twin fluorescent lamp with accessories LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Form the circuit for a fluorescent lamp of a given size for domestic and industrial purposes  Connect a fluorescent lamp with accessories and install  Connect a twin-tube fluorescent lamp with accessories, capacitor in series with one tube CIRCUIT DIAGRAM MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 Twin Tube light fitting set 1200mm / 220V /40W 1 set 2 Fluorescent lamp 40W / 230V 2 nos. 3 Starter 40W / 230V 2 nos. 4 Capacitor 3.15 MFD /380V 2 nos. TOOLS REQUIRED  Test lamp 60W with lead - 1 no.  Cutting pliers 150mm - 1 no.  Connector screwdriver 100mm - 1 no.  Screwdriver 150mm - 1 no.
  • 74.
    68 PROCEDURE AND OBSERVATION(PARALLEL CONNECTION) 1. Check the choke for its short and open with a test lamp as shown in fig and record the results. 2. Check the starter with a series test lamp as shown in Fig. Observe the flickering of the lamp which indicates good condition of the starter. 3. Connect the accessories a per the circuit diagram for the 1200mm tube lights 4. Fix the starters and fluorescent lamps, connect the fitting to the supply and test. SAFETY PRECAUTION  Terminate the leads to a connector for connecting to the supply
  • 75.
    69 NAME OF THEEXPERIMENT One Light control by switch LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Connect a lamp controlling through single pole switch CIRCUIT DIAGRAM MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical product required 1 S P Switch 230V / 6A 1 no. 2 Switch holder 1 no. 3 Wires PVC pipes 2.5 sq.mm ¾ inch as reqd. as reqd. 4 Saddles Screws ¾ inch ¾ inch as reqd. as reqd. TOOLS REQUIRED  Screwdriver set - 1 no.  Cutting pliers - 1 no.  Neon tester - 1 no.  Electrician knife - 1 no.  Wire stripper - 1 no. PROCEDURE AND OBSERVATION 1. Fix the switch, batten holder at particular places. 2. Fix the pipes with saddles connecting holders and switch. 3. Draw the wires through the pipes and connect them according to circuit diagram. 4. Switch ON SAFETY PRECAUTION  Care should be taken while using tools.  Connect phase wire through switch only.  Connections should be tight.
  • 76.
    70 NAME OF THEEXPERIMENT 3-pin socket control by switch LEARNING OBJECTIVES At the end of the exercise the aspirant will be able to  Connect a 3-pin socket controlling by a switch CIRCUIT DIAGRAM MATERIAL REQUIRED Sl No Material required Specification (rating) Qty Schneider electrical products required 1 S P Switch 220V / 6A 1 no. yes 2 3-pin socket 220V /6A 1 no. yes 3 PVC pipes ¾ inch as reqd. 4 Wire, Screws as reqd. PROCEDURE AND OBSERVATION 5. Fix the switch, batten holder at particular places. 6. Fix the pipes with saddles connecting holders and switch. 7. Draw the wires through the pipes and connect them according to circuit diagram. 8. Switch ON SAFETY PRECAUTION  Care should be taken while using tools.  Connect phase wire through switch only.  Connections should be tight.
  • 77.
    71 NAME OF THEEXPERIMENT Complete wiring of a room LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Fix electrical circuit in the room. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Energy Meter --- --- --- 1 Nos. --- --- --- S.P. MCB 10 Amps. 1 Nos. Yes S.P. Switch 06 Amps. 1 Nos. Yes 3 Pin Socket --- --- --- 1 Nos. Yes Fuse, Lamp, Batten Holder --- --- --- 1 + 1 Nos. --- --- --- P.V.C Pipes and Wires, Screw Shaddle As Per Required --- --- --- --- --- --- TOOLS REQUIRED: 01. Cutting Plier 02. Nose Plier 03. Electrician Knife 04. Wire Stripper 05. Pocker 06. Screw Driver Set 07. Hammer 08. Flat Screw Driver 09. Neon Tester PROCEDURE AND OBSERVATIONS 01. Keep ready all tools / materials. 02. Fix the energy meter MCB & Fuse on a wood board.
  • 78.
    72 03. Fix theswitches & socket on another board. 04. Now fix the pipes connecting all accessories in a systematic manner. 05. Draw & connect all as per the circuit. 06. Ensure all are working properly & try to note the energy meter readings. SAFETY PRECAUTIONS 01. Connect energy meter connecting properly. 02. Fuse & MCB should be through phase wire any. 03. Do not short in socket, holder etc. 04. Connections should be tight.
  • 79.
    73 NAME OF THEEXPERIMENT 2 Light Control by 2 Switches LEARNING OBJECTIVES: 01. Parallel connection of 2 lights. 02. Lights controlled individually. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Switch 220 V 16 Amps. 2 Nos. Yes Battern Holder with Lamps --- --- --- 2 Nos. Yes 1 P.V.C Pipes As Per Required --- --- --- --- --- --- Wires As Per Required --- --- --- --- --- --- Saddles/ Screws As Per Required --- --- --- --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Wire Stripper 03. Screw Driver Set 04. Neon Tester 05. Electrician Knife PROCEDURE AND OBSERVATIONS 01. Fix the switches, batten holders at proper places. 02. Fix the PVC pipes with saddles so that it connects holders & switches. 03. Draw and connect the wires through the pipes as per the circuit diagram. 04. Ensure the proper lumination of the experiment done. SAFETY PRECAUTIONS 01. Ensure the connections before giving supply. 02. Never connect neutral switches 03. Do not use broken accessories.
  • 80.
    74 NAME OF THEEXPERIMENT Prepare a pipe earth and measure the earth electrode resistance LEARNING OBJECTIVES Objectives: At the end of this exercise you shall be able to  Dig an earth pit  Prepare a pipe earth according to B.I.S. specification.  Measure the resistance of the earth electrode  CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED G.I. pipe 12.7 mm dia. 5 m. --- --- --- G.I. bend 12.7 mm dia. 2 Nos. --- --- --- C.I. cover hinged to C.I. frame 300 mm square 1 No. --- --- --- G.I pipe 19 mm dia. 1 m. --- --- --- G.I. pipe 38 mm dia. having 12 mm dia. holes 2.5 m --- --- --- Reducer 38 x 19 mm 1 No. --- --- --- Funnel with 19 mm dia. sleeve 1 No. --- --- ---
  • 81.
    75 & wire mesh G.I.nut for 19 mm dia. sleeve & wire mesh 1 No. --- --- --- G.I. check – nuts for G.I pipe 19 mm dia. 4 Nos. --- --- --- G.I. washer 40 mm with 19 mm hole 1 No. --- --- --- G.I. wire No.8 SWG 10 m --- --- --- Copper lug 200 amps with 19 mm dia. hole 1 No. --- --- --- Solder 60 / 40 100 gms. --- --- --- Match box --- --- --- 1 No. --- --- --- Soldering paste --- --- --- 10 gms. --- --- --- Cement --- --- --- 10 Kgs. --- --- --- Blue metal chips 6 mm size 40 Kgs. --- --- --- River sand --- --- --- 80 Kgs. --- --- --- Salt (common) --- --- --- 3 bags --- --- --- Coke or charcoal --- --- --- 3 bags --- --- --- TOOLS REQUIRED  G.I. die stock with 12.7 mm, 19 mm and 38 mm dies 1 set  D.E spanners 5 mm to 20 mm 1 set of eight  Blow lamp, 1 litre with kerosene 1 No.  Crowbar, hexagonal 1800 mm long 1 No.  Powrah (spade) 1 No  Cement mortar tray 2 Nos.  Tongs 300 mm 1 No.  Measuring tape 5 m 1 No.  Ladle 2 Nos.  Combination pliers 200 mm 1 No.  Pipe wrench 50 mm 1 No.  Hacksaw with 32 T.P.I blade 1 No.  Wooden box 150 (l) x 150 (b) x 300 (h) mm 1 No.  Soldering pot (melting) 1 No. EQUIPMENT / MACHINES  Earth tester with connecting leads and spikes 1 No. PROCEDURE AND OBSERVATIONS 01. Collect G.I. pipes and the accessories. 02. Make a slant cut of 30 in the 38 mm dia. G.I. pipe to have sharp edge as shown in Fig. 1. 03. Make threads in the other end of 30 mm dia. G.I. pipe to a length of 25 mm. 04. Make threads in both ends of 19 mm dia. G.I. pipes to a length of 25 mm on one side and 75 mm on the other side. 05. Fabricate the 38 mm and 19 mm dia. G.I. pipes as shown in Fig. 1 06. Select an earth pit site at least 1.5 meters away from the building foundation. 07. Dig an earth pit of dimensions 1 m width x 1m breadth x 3.75 m depth. 08. Place the fabricated pipe in an upright position as shown in Fig. 1 and position the pipe with help of bamboo sticks. 09. Place the wooden box around the pipe and fill it to a height of about 15 cm with charcoal, and fill the surrounding outer space of the box with soil.
  • 82.
    76 10. Lift andplace the wooden box above the coke layer. Fill up with salt to a height of about 15 cm and to an area of 150 x 150 mm area around the pipe. 11. Repeat the above steps 10 and 11 up to 2.5 meters as shown in Fig. 1 12. Place the G.I. Pipe 12.7 mm dia. with G.I. bends in proper position for E.C.C connection. 13. Prepare the concrete mixture and build the structure as shown in Fig. 1. 14. Fix the G.I. cover also 15. Insert the G.I. wire No. 8 SWG through the 12.7 mm dia. G.I. pipe. 16. Use the ladle and the blowlamp and melt the solder. 17. Solder the lug in the G.I. wire. 18. Insert the lug in the 19 mm dia. G.I. pipe and tighten it with G.I. nut and check nut. 19. Pour three or four buckets of water through the funnel. 20. Test the earth electrode resistance with an earth megger. (The method of measuring earth resistance is given in Ex. 306. Follow the procedure. The earth continuity conductor (E.C.C.) should not be connected to the earth electrode resistance has been given earlier. Check the value. 21. Enter the value of the earth electrode resistance in column 5 of Table 1. Fill up the other particulars also. The acceptable value of the earth electrode resistance has been given earlier. Check the value. 22. If the earth resistance is found higher than the acceptable value, make one more pipe earth electrode at a distance of 8 meters from the earlier one and connect both of them in parallel. 23. Measure the earth electrode value and enter it in column 6 of Table 1. SAFETY PRECAUTIONS 01. An earth electrode should not be installed in proximity to a metal fence to avoid the possibility of the fence becoming negative. If the metal fence is unavoidable. It should be earthed. 02. The depth given here is the minimum recommended. However, the depth may be increases till moist soil is reached. 03. Allow an hour for the water to be absorbed in the earth. 04. The second reading with two electrodes will be approximately half the first reading will be approximately half the first reading which was taken with one electrode. The measured value should be within the recommended value. If not, you may have to go for another earth electrode at a distance of 8 meters from the other electrodes.
  • 83.
    77 NAME OF THEEXPERIMENT Fixing of tube light fitting LEARNING OBJECTIVEs  At the end of this exercise you shall be able to  Form a circuit for fluorescent lamps of a given size for domestic purposes.  Connect a fluorescent lamp with accessories and install it. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Tube light fitting with all accessories --- --- --- 1 No. --- --- --- Wooden Guttar screws --- --- --- 2 Nos. 2 Nos. --- --- --- Adopter --- --- --- 1 No. --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Flat Screw Driver 03. Neon Tester 04. Screw Driver Set 05. Hammer 06. Drill Machine 07. Pocker 08. Wire Stripper PROCEDURE AND OBSERVATIONS 1. Check the choke for its short and open with a test lamp and record the results. 2. Check the starter with a series test lamp. Observe the flickering of the lamp which indicates good condition of the starter. 3. Assemble the following fluorescent tube accessories in the fitting base. Refer to the Sketch. 4. Connect the accessories as shown in Fig. Also install the tested meter.
  • 84.
    78 5. Test thefilament on both sides of the fluorescent tube for its continuity as shown in Fig. 5. Discard the fluorescent tube with open of fused filament in either side. 6. Fix the bulb in the holder.  Firstly, you have to make sure that the slot in the inner parts of the holder is turned to the proper position.  Then insert both the ends (pins) into the holder of the fittings on either side of the tube. One end is shown in Fig. 6 Push the socket pins all the way into the fittings until you feel that you can turn the tube in the sockets. SAFETY PRECAUTIONS 01. Be careful not to bend the pins at either end of the tube. 02. The fixing of the tube to the wall, ceiling or tubular post should be strong enough to support the weight of the fitting. 03. The installed fitting must be below the level of the ceiling fan to avoid the flickering effect of the shadow. 04. Check the supply at the ceiling rose. Switch off the supply at the ceiling rose. Switch off the supply before making any connection.
  • 85.
    79 NAME OF THEEXPERIMENT Complete wiring of 1 bhk house LEARNING OBJECTIVES o Planning estimation & costing of wiring of 1 BHK house with all connections. o Learning more about switch & socket, fan connection etc. CIRCUIT DIAGRAM TOOLS REQUIRED 01. Cutting Plier 02. Nose Plier 03. Wire Stripper / Electrician Knife 04. Wire Cutter 05. Hammer 06. Drilling Machine 07. Chiesel 08. Junper 09. Cutting Machine 10. Screw Driver Set 11. Neon Tester 12. Screw Driver SAFETY PRECAUTIONS 01. Take care should be taken while using electrical accessories / tools. 02. Aware of injuries while hammering etc. 03. Connect only phase wire through switches. 04. Avoid loose connections / change broken accessories.
  • 86.
    80 MATERIALS REQUIRED MATERIAL REQUIREDSPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED S.P Switch 5 Amp / 230 V 09 Yes 3 Pin Socket 5 Amp / 230 V 03 Yes Batten Holder, Ceiling Rose 5 Amp / 230 V 04 02 --- --- --- M.C.B 10 AMP / 230 V 01 --- --- --- Fuse Cut out 10 AMP / 230 V 01 Yes Wire, PVC, Pipe, Saddles, Screws All as per reqd. --- --- --- Wood Board + Box All as per reqd. --- --- --- PROCEDURE AND OBSERVATIONS a. Mark the location of the control points, out led points cable run in the given lay out drawing of bed room. b. Tube light and fan control by a switch near the entrance. c. The cable routing of the room insulation has to be carried out only in either straight and horizontal and vertical cable run. d. Mark the position of the control point outlet points and cable run on the wall surface of the wall.
  • 87.
    81 NAME OF THEEXPERIMENT Service, repair and install a ceiling fan LEARNING OBJECTIVES Objectives: At the end of this exercise the aspirant will be able to  Test the given ceiling fan for its working.  Dismantle the ceiling fan.  Trace and identify (or) locate faults in the ceiling fan.  Replace faulty parts with good / rectified ones.  Test the capacitors  Clean and lubricate the bearings  Test the motor winding for continuity  Check the speed regulator  Assemble the ceiling fan and test for its working. CIRCUIT DIAGRAM REQUIREMENTS Tools / Instruments 01. D.E spanner set (6mm to 22 mm) 1 No. 02. Screw driver 100 mm, 150 mm each 1 No. 03. Heavy duty screwdriver (300 mm x 8 mm) 1 No. 04. Megger 500 V 1 No. Equipments / Machines 01. Different makes of ceiling fans 3 Nos. Materials 01. Connecting leads as reqd. 02. Crease for bearing as reqd. 03. Insulation tape P.V.C. as reqd. 04. Test lamp 230 V 40 W 1 No.
  • 88.
    82 Fig 1 Fig2 Fig 3 Fig 4 Fig 5 Fig 6
  • 89.
    83 PROCEDURE Task 1: Servicing 01.Switch “ON” the fan and check for its smooth functioning at different settings of the regulator. 02. Isolate the fan circuit from supply by  Removing the circuit cu – out or  Switching off the mains and removing the fuse units. 03. Conduct visual inspection  For good condition of switch  For proper mounting of regulator and firm fitting of knob. 04. Open the switch over. Remove any external deposits, using a hair brush. 05. Check firmness of termination. Open the regulator and clean the inside with a brush. Check and adjust the contract, terminations (Fig 1) 06. Measure the insulation resistance between the outgoing terminals of the regulator and earth. (Fig 2) Record its value in Table 1. 07. Make arrangements to reach to the ceiling fan through stable means of elevation. (Ladder, table etc. the safety of a person is of utmost importance. Fig 3) 08. Note down the visual marking made on the fan, if any, and the name plate details for filling up the entries in Table 1. 09. Remove the fan blades in succession and refit the screws and spring washers in their place, in the body of the fan. 10. Slide the top and bottom canopies for inspection and cleaning. (Fig 4) 11. Inspect the supporting hook, grommet, shackle, supporting system, split pin etc. 12. Inspect the cotter pin, check nut, connections to the capacitor, fan leads, connector (Fig 5). Clean the external dust, dirt with a brush. 13. Clean the fan body first with a dry cloth and then with a wet cloth. 14. On inspection after sliding the canopy, if any excess of moisture or water is found, bring the fan down with the rod for testing its insulation resistance. 15. Dry the fan body by external heating with 500 W or 1000 W bulb or in an oven. If insulation is weak due to dampness. 16. Clean the blades thoroughly and mount them back. Apply grease / oil the screws at the time of fixing the blade. 17. Test the fan for its smooth functioning, after resuming supply to the fan circuit. 18. Record your observations about the points listed in Table 2. TABLE 1 Name of appliance: Serial No. Voltage Sweep Make Supply Current Watts Special Marking Insulation resistance between terminal & body Megohms Date of servicing Recommended repair / replacement made, if any TABLE 2 Sl.No. Points to be observed Condition Normal Abnormal 01. Speed 02. Noise 03. Heat (after 10 min. run) 04. Wobbling 05. Function of regulator in all positions
  • 90.
    84 Task 2: Repairing Listento the user‟s complaints. Complaints may be  Fan is not running  Fan is noisy  Fan wobbles excessively  Motor runs hot. Fan is not running 01. If there is no incoming supply to the fan, check the concerned branch circuit fuse and ensure the availability of supply in the fan circuit. 02. Check for the supply in the outgoing lead from the regulator to the fan. If any fault is noticed in the switch and / or regulator, rectify it. 03. Ensure free rotation of the fan by rotating it manually. 04. Check the supply at the fan terminals (either at the fan terminals or at the ceiling rose.) 05. Give temporary connection for further testing, if there is no supply at the ceiling rose. 06. If even after step 5 is done, the fan is not running, check the connection of the capacitor for loose connection after switching off the supply. 07. Switch ON the supply. If the fan is not running, the cause may be a defective capacitor. 08. Replace the capacitor with an identical good capacitor. 09. If even after replacing the capacitor the fan is not running, lower the fan and send it for testing of winding, and for necessary repair. Fan is noisy: 01. Collect the history and nature of the noise of the fan from the user. 02. Run the fan and observe the noise. Identify whether the noise is due to one or a combination of the following (The parts are shown in Fig 6.) a. Slack canopy – touching the rotating body. b. Worm out / partly out shackle. c. Loose element of the blade. d. Loose or missing screws. e. Capacitor housing slack. f. Broken or worn out split pin at the top and bottom. g. Lack of lubrication, or dirt in bearing. h. Worn out bearing / bush. i. Blade distortion / breakage. j. Alignment of blades. Fan Wobbles excessively 01. Check to be sure that the screws which attach the fan blade flanges to the motor hub are tight. 02. Check to be sure that the fan blade flanges seat firmly and uniformly to the surface of the motor hub. If the flanges are seated incorrectly, loosen the flange screws and re tighten. 03. Tighten the hanger bracket screws to the junction box, secure the hook. 04. Interchange the adjacent (side by side) pair of blades. If the fan blades are out of balance, it can redistribute the weight and result in smoother operation. Motor runs hot. 01. Check for partial short circuit in winding. If defective, send it for rewinding. 02. Check for tight bearing, if it is defective, replace it with good bearing. Repeat the above steps for 3 different makes.
  • 91.
    85 Task 3: Installationof fan 01. Cut selects the down rod length such that the blades remain at 2.4 to 2.7 m above the floor. Do not mix the blades of one set with another set as the blades are matched as a set. 02. Insert the connection wires and then slip in the canopies back to back through the down rod. 03. Insert the down rod on the spindle and tighten with the bolt and nut separately packed with the hanger clamp. (Fig 6) 04. Remove the bolt and nut from the hanger assembly. (Fig 7) 05. Insert the down rod top end in the hanger clamp assembly and tighten with bolt and nut. Providing spilt pin, cotter pin at both ends of the down rod in a fan is almost to prevent falling of the fan by slackening of the bolt / nut securing. 06. Connect the wires to the terminal block, as per the instructions of the manufacturer. 07. Refit the bolt, nut with rubber shackle in the hanger clamp assembly. 08. Suspend the fan (without blades) by a pipe or rod inserted through the shackle as shown in Fig 8. 09. Connect it to the rated supply for a short while and observe for smooth running in the proper direction. 10. Mount the fan in the ceiling hook / supporting hook. Ensure the split pin is inserted in the bolt and bent/or the lock nut is fitted. 11. Connect the wires to the ceiling rose. Slacken, slide and fix the canopies to voer the top hook and spindle terminals block and capacitor. Ensure that the canopies are fitted with just sufficient spacing. 12. Fox the blade with screws already provided on the motor.
  • 92.
    86 NAME OF THEEXPERIMENT Fan controlled by regulator through switch LEARNING OBJECTIVES  How to connect a fan through regulator CIRCUIT DIAGRAM Fig 7 Fig 8 Fig 9 MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED P switch fan regulator 6 A – 250 V 1 No. Yes Ceiling rose, ceiling fan --- --- --- 1 No. 1 No. --- --- --- PVC pipes, saddles / screws --- --- --- 1 No. --- --- ---
  • 93.
    87 Task 4: Installationof fan regulator Read the manufacturer‟s instructions and diagram of the regulator connection and follow the instructions. 01. Installation of a fan regulator of a particular type. 02. Loosen the screw (1) inside the knob with the help of a small screwdriver. (Fig 9) 03. Lift the knob (2) by a screwdriver. (Fig 9) 04. Remove top cover (4) by unscrewing the two screws (3) under the knob (Fig 9) 05. Take out the wires through the base plate and make a series electrical connection at the switch. 06. Fix the base plate to the wall. 07. Fix the top cover by the screws and insert the knob. 08. Tighten the knob by the grub screw (1). 09. Test the fan for its working by connecting to the supply. TOOLS REQUIRED: 01. Cutting Plier. 02. Neon Tester 03. Wire Stripper / Electrician Knife 04. Dousce End Spanner 05. Screw Driver Set PROCEDURE AND OBSERVATIONS: 01. Fix the switch & regulator at particular places. 02. Connect regulator in series with the switch. (Refer circuit diagram) 03. Check the fan is fitted perfectly. 04. Fist switch on the switch and then operate the regulator. 05. Check the fan is working or not. SAFETY PRECAUTIONS: 01. Never connect neutral wire to regulator / switch. 02. Fix the cover before giving supply. 03. Ensure the connections.
  • 94.
    88 NAME OF THEEXPERIMENT Power sockets controlled by DP switches LEARNING OBJECTIVES  Knowing connection from D.P to power socket.  Phase wire and neutral wire controlled by switch.  Do not make short in socket. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Main Switch Double Pole Switch 25 – 32 Amp 230 V 16 Amp – 230 V 1 2 Lamp Water Heater 6 Amp – 230 V 230 V 1 1 Wire, wooden box, saddle, screws As per reqd. All items TOOLS REQUIRED 01. Cutting Pliers 02. Electrician Knife 03. Screw Driver, Flat & Philip 04. Neon Tester 05. As per required wire, and others SAFETY PRECAUTIONS 01. Do not make short circuits. 02. Phase and neutral controlled by switches. 03. Water heater must be fixed proper insulation otherwise, shock water leaking etc. PROCEDURE AND OBSERVATIONS: 01. Fix the DP switches side by side in wood box. 02. Draw 4 Sq.mm wire & 2.5 Sq. mm wire separately from the mains 03. Connect 2.5 / 4 Sq. mm wire 2 DP switches fix so that it connects lighting and heating circuits respectively.
  • 95.
    89 NAME OF EXPERIMENT Completewiring of 2 bhk house LEARNING OBJECTIVE 01. Planning and estimation and costing of a wiring of 2 BHK with all connection telephone, cable sockets, learn more of the switches and earth and energy meter must be fixed on proper place: Ex. 515 Pg. 299. CIRCUIT DIAGRAM: Follow the diagram of No. 1 BHK, MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Ceiling Fan --- --- --- 3 Nos. --- --- --- DP Switches 220 V / 5A 10 Nos. Yes Florescent Tube with hlder --- --- --- 4 Nos. --- --- --- Fuse, Socket 16 A – 230 V 7 Nos. Yes --- --- --- 3 Nos. --- --- --- PVC Wires and screws wall As per reqd. --- --- - -- --- --- --- As per reqd. --- --- - -- --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Electrician Knife 03. Ball Peen Hammer 04. Screw Driver, Flat & Philip 05. Neon Tester 06. Hand Drill with Drill Bits (all types) 07. Wire Cutter, Stripper 08. Long Nose Pliers. PROCEDURE AND OBSERVATIONS: 01. One light near the bed controlled by 2 switches. 02. One tub light controlled by a switch near the centre. 03. Wall sockets controlled by switches. 04. Mark the location of the entry and exit point of the supply in the bed room layout by study the building plan. SAFETY PRECAUTIONS 01. While the wiring is going on take care of connect for switches and power sockets. 02. Carefully working for drill and hammering. 03. Connection must be tight properly (not loose). 04. Earth must be proper fixing.
  • 96.
    90 NAME OF THEEXPERIMENT 5 lights controlled by 5 switches LEARNING OBJECTIVE: Parallel connection of 5 lights. Lights controlled individually CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Lamp Holders --- --- --- 5 Nos. Yes DP Switch 230 V (6 A) 5 Nos. Yes Lamp --- --- --- 5 Nos. --- --- --- Screws and wires As per reqd. --- --- - -- --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Electrician Knife 03. Screw Driver, Flat & Philip 05. Neon Tester 06. Cutter for Wire, Stripper SAFETY PRECAUTIONS 01. Ensure the connections before giving supply. 02. Do the wiring through the bitted pipes & connect them as per the circuit. 03. Tapping of neutral / phase wire should be tight. 04. Check the wiring system with instructor and give the supply.
  • 97.
    91 NAME OF THEEXPERIMENT Telephone and cable sockets LEARNING OBJECTIVE: Connection and socket knowing M / F sockets. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED T.V Cable Socket --- --- --- 01 --- --- --- Telephone Socket --- --- --- 01 --- --- --- Telephone Wire & Cable Wire --- --- --- As per Reqd. --- --- --- TOOLS REQUIRED 01. Cutting Plier 02. Electrician Knife 03. Wire Cutter & Stripper 05. Neon Tester or Screw Driver PROCEDURE AND OBSERVATIONS: 01. Fix proper terminal for cable socket. 02. After fixing cable check T.V picture. 03. Do soldering for the sockets. SAFETY PRECAUTIONS 01. T.V Cable and telephone line must be fixing the light properly. 02. Drawing these cables in separate pipes with an advantage and safe.
  • 98.
    92 NAME OF THEEXPERIMENT Complete wiring of a 3 bhk LEARNING OBJECTIVE  Draw the plan of the rooms from house plan to a larger scale.  Locate the entry and exit points of the electric supply in the room.  Locate the position of electrical accessories according to requirement and prepare a layout diagram using B.I.S symbols and etc. PLAN CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Ceiling Fan DP Switch --- --- --- 5 A – 230 V 5 Nos. 15 Nos. --- --- --- Socket 230 V – 16 Amp 3 Nos. Yes Fluorescent Tube 40 Watt 5 Nos. --- --- --- Socket 230 V – 6 Amp 6 Nos. Yes Holders Wires As per reqd. 7 Nos. 7 Nos. --- --- --- Emergency socket Pump 16 Amp I.H.P (220 to 250 V) 3 Nos. 1 Nos. Yes PROCEDURE AND OBSERVATIONS a. Mark the location of the control points out let points and cable run the house. b. One light near the bed controlled from two places. c. One tube light controlled by a switch near the entrance. d. One fan at the center of the bedroom controlled by a switch and regulator near the entrance. e. The cable of routing of the room installation has to be carried out only in either straight and horizontal and vertical cable run. TOOLS REQUIRED 1. Cutting Pliers Wire Cutter & Stripper 2. Nose Pliers Drill Machine 3. Screw Driver Flat + Phillip Electrician Knife 4. Hammer + Drill Ladder + Steal measuring tape 5 mt. SAFETY PRECAUTIONS 1. Fixing the electrical accessories carefully handling. 2. Fixing the switches and socket not to be over eight. 3. Don‟t leave anything in the circuit board. 4. Carefully hammering and drilling.
  • 99.
    93 NAME OF THEEXPERIMENT Hotel and Mini lodge of 6 rooms LEARNING OBJECTIVE  Plan of wiring and estimation and costing and making connections as per diagram of 6 rooms.  Decide how to route the connecting cable and main cable in the bedrooms taking into consideration aesthetic economic and labour aspects in the layout.  Mark the location of the entry and exit points of the supply in the bed room. CIRCUIT DIAGRAM TOOLS REQUIRED o Cutting Plier o Wire Cutter & Stripper o Nose Pliers & Electrician Knife o Hammer +Drill Machine o Screw Driver Flat + Neon Tester + Test lamp MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Bell Push 220 V (6 Amps) 6 Nos. Lamp indicating --- --- --- 6 Nos. --- --- --- Holders --- --- --- 6 Nos. Calling Bell --- --- --- 1 Nos. PVC Pipe & Wire As per Reqd. --- --- - -- --- --- ---
  • 100.
    94 PROCEDURE AND OBSERVATIONS: 1.Fix the all lights at one place on to bell (also mark them) different places. 2. Now fix the PVC pipes so that it connects switches and lamp holders. 3. Draw the wires as required inside the pipe and do the wiring / connect the bell pushes and lamp holders as per circuit diagram. 4. Do the wiring neatly. 5. Test the system for proper working. 6. Connect only phase wire to the switch control. SAFETY PRECAUTIONS Carefully work of the Electrical items + Connect only phase wire to the switch control
  • 101.
    95 NAME OF THEEXPERIMENT Wiring Of Corridor Lighting LEARNING OBJECTIVE 01. The corridor has a number of lamps 02. Each lamp has a controlled by a 2 switches. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED Lamps & Holders --- --- --- 4 Nos. 4 Nos. --- --- --- Switches (Two Way) 220 V (6 Amp) 4 Nos. Yes P.V.C Wires As per required --- --- - -- --- --- --- PROCEDURE AND OBSERVATIONS 01. Each lamp are L1, L2, L3 and L4 are different lamps having controls at S1, S1, S2, S2, S3, S3, and S4, S4 respectively. TOOLS REQUIRED 01. Cutting Pliers 02. Nose Pliers and Electrical Knife 03. Wire Cutter and Stripper 04. Hammer, Screw Driver Flat and Philip 05. Neon Tester and Test Lamp SAFETY PRECAUTIONS 01. In two way switches operate the switching knob of the pairs alternatively to check the polarity 02. Properly fix the phase control to the switch.
  • 102.
    96 NAME OF THEEXPERIMENT Identify 3 phases (4 wires) and know about the D.O.L Starter LEARNING OBJECTIVE Objective: At the end of this exercise you shall be able to a. Identify and collect the parts of a D.O.L starter. b. Assemble the D.O.L starter when contactor overload relay, push button stations and single strand cables are given in semi – knocked out condition. c. Connect and harness the hook – up cable for control circuit. d. Mount the D.O.L starter, the main ICTP switch and connect the 3 Phase induction motor e. Earth the motor, the starter and the switch f. Set the overload relay ® g. Replace correct capacity back up fuses. h. Start and stop the 3 – Phase induction motor through D.O.L starter. i. Measure the starting and the running currents of the 3 – Phase squirrel cage motor. j. Determine synchronous speed, slip and percentage slip. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED 3 Phase motor DOL starter 5 HP 10 A – 415 V with OLR 1 1 --- --- --- Single strand copper wire 165 WG 0.5 m --- --- --- Single strand wire 185 WG 0.5 m --- --- --- CTP Switch 16 A – 415 U 01 --- --- ---
  • 103.
    97 TOOLS REQUIRED a. Combinationpliers 200 mm b. Screw driver 300 mm with 4 mm blade c. Connector screw driver 100 mm d. Side cutting pliers 200 mm e. Electrician Knife f. Ammeter MI 0 – 20 amp g. Voltmeter MI 500 V h. Plumb bob with thread i. Spirit level j. Tachometer 0 – 3000 rpm PROCEDURE AND OBSERVATIONS 1. Note down the name plate details of the given AC 3 phase squirrel cage induction motor in Table 1. 2. Collect the contactor unit. Overloads relay unit, start / stop push button unit, the necessary fixing screws, hook up cables, I.C.T.P switch and D.O.L starter base and cover. 3. List the items you received from your instructor in Table 4. Record the name plate details of the contactor and overload relay in your record respectively. 5. Investigate and check the contactor input and output terminals, auxiliary and main terminals, movable and fixed contacts, no – volt coil, overload relay, their rating normally closed relay contacts and their operation. 6. Identify the connecting terminals for interconnecting no – volt coil, main supply to control circuit, normally open auxiliary contracts. 7. Identify the mounting screw holes in the contactor, overload relay and the corresponding holes in the starter base box. 8. Draw the complete circuit diagram for the given D.O.L starter with overload relay, no – volt coil, „ON‟ and „OFF‟ push buttons. 9. Get the diagram approved by the instructor. 10. Mount the accessories in the starter base box with the help of mounting screws. 11. Identify the place of connection of the hook up cables with the help of the approved diagram. Measure and cut the hook up cables leaving allowance for harnessing. 12. Connect the hook up cables according to the approved diagram. 13. Harness the hook up cables such that the cables do not interfere with any moving mechanism of the starter. 14. Check up once again the complete connection of the D.O.L starter internal wiring. 15. Get the wiring approved by your instructor. 16. Identify the holes in the starter base box for mounting the starter on the wall / frame. 17. Mount the starter vertically on the wall / frame. 18. Connect the main supply to the starter incoming terminals through the I.C.T.P switch. 19. Connect the starter outgoing terminals to the 3 phase squirrel caged induction motor along with the ammeter and voltmeter. 20. Connect the protective earthing continuity conductors to the main earth. 21. Investigate the full load current of the motor and set the overload relay of the starter to that rating. 22. Provide a back up fuse as recommended by the manufacturer of the starter considering the horse power rating of the motor. 23. Get the main connections, earth connections, overload setting and the backup fuse rating approved by your instructor. 24. Switch on the ICTP.
  • 104.
    98 25. Start themotor by the start (S) button of the starter. 26. Read the ammeter for the starting current at the time of starting. 27. Read the voltmeter and ammeter values when the motor shows normal running. 28. Measure the actual speed of the rotor with the help of a tachometer. 29. Switch OFF the motor using stop (S2) button of the starter. 30. Switch OFF the mains, remove the fuses and disconnect the connections. 31. Determine the synchronous speed and enter the value in Table. 32. Show the readings to your instructor. SAFETY PRECAUTIONS 1. Do not tighten the screws more than necessary as too much tightening of screws will break the PVC casing of the contactor and OL relay. 2. The position of the starter should be such that the no – volt coil mechanism works properly, taking advantage of the gravitational pull while disengaging. 3. Before connecting the 3 phase squirrel cage motor, test it for continuity and insulation. 4. Preferably check for the backup fuse rating in the pamphlet supplied along with your starter.
  • 105.
    99 NAME OF THEEXPERIMENT Manual Star – Delta Starter LEARNING OBJECTIVES At the end of this exercise you shall be able to identify the parts of a manual star – delta and trace the connection. 1. Draw the star / delta connection of motor winding through starter – handle operation. 2. Provide proper back up fuse in the main switch of the 3 phase squirrel cage motor according to the motor rating. 3. Connect the manual star – delta starter with 3 – phase squirrel cage induction motor. 4. Adjust the overload relay according to the motor current rating. 5. Start the 3 – Phase squirrel cage induction motor through the manual star – delta starter. 6. Stop the 3 phase squirrel cage induction motor through the manual star – delta starter. 7. Reverse the direction of rotation of the squirrel cage motor. CIRCUIT DIAGRAM MATERIALS REQUIRED MATERIAL REQUIRED SPECIFICATION (RATING) QTY SCHNEIDER ELECTRICAL PRODUCTS REQUIRED PH Motor Star + Delta starter 10 HP – 10 – 15 amps, 415.V. 3 PH 01 C. insulated stranded 2.5 sq mm - 650 V 25 DP Switch 16 A – 415 V / 3P 01 Schneider Material As per required TOOLS REQUIRED 1. Insulated cutting pliers 200 mm 1 No. 2. Screw driver 200 mm, 300 mm 1 No. each 3. Side cutter 150 mm 1 No.
  • 106.
    100 4. Wire stripper1 No. 5. M.I ammeter 10 amp 1 No. 6. M.I Voltmeter 0 – 500 V 1 No. PROCEDURE AND OBSERVATIONS 1. Read and interpret the name – plate details of the given 3 – phase induction motor and starter and enter in Tables 1 (as per Exercise 1004) & 2. 2. Switch „off‟ the mains, remove the fuse – carriers and keep them in safe custody. 3. Remove the terminal cover of the motor and the front cover of the starter. 4. Indentify the parts of the given star – delta starter, trace the connections and study its operation. Draw the traced out circuit and get it approved by the instructor, 5. Draw the complete connection diagram incorporating the ICTP switch the given star – delta starter and motor and get it approved by your instructor. 6. Make the connections of the motor, starter and the ICTP switch as per the approved diagram. 7. Connect three cables from supply L1, L2 & L3 to the main. 8. Insert the ammeter in series with one of the line cables from the main switch and a voltmeter across two line cables. 9. Swire proper fuse element according to the given motor rating in the fuse carrier and insert the carriers and insert the carriers in the main switch. 10. Set the overload relay according to the full load current rating of the motor. 11. Provide double earth to the metal body of the main switch, starter and the motor frame. 12. Switch on the main, observe the voltmeter reading and move the handle to the star position positively and at the same time observe the starting current and enter it in Table. 13. Allow the motor to start, race initially and let the sound of the rotating shaft come to a steady state; then move the handle to the deita position positively. 14. Note down the direction of rotation and enter it in Table. 15. Note down the current taken by the motor in running condition and enter the value of the current in Table 3. 16. Then stop the motor by pressing the stop – button of the starter. 17. Switch „OFF‟ the main switch and remove the fuses. 18. Interchange the two line cables R‟ and Y‟ to terminals L2 and L1 respectively as shown in Fig 19. Insert the fuse carries in the main switch. 20. Repeat steps No. 12 to 15 and record the information in Tables. 21. Stop the motor, switch off the supply and remove the fuse; then interchange the line cables Y‟ and B‟ terminals L3 and L1 respectively as shown in Fig. 22. Insert the fuse carries in the main switch. 23. Repeat steps Nos. 13 to 16 and record the information in Tables. 24. Stop the motor and write your observations about the method of changing the direction of rotation. 25. Switch „off‟ the mains, remove the fuse – carriers and remove all connections. SAFETY PRECAUTIONS 1. To connect a star – delta, the squirrel cage induction motor must have six terminals, which are normally marked as U1, V1, W1 & U2, V2, W2. 2. Assumption: Check the connections for correctness and tightness. Get it approved by the instructor.
  • 107.
    101 NAME OF THEEXPERIMENT Replace the heating element in a non-automatic electric iron and test LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Measure insulation resistance between the terminals and the body of the electric iron (R)  Test the given electric iron for its working (R)  Test the line cord for continuity (R)  Dismantle an electric iron  Trace and identify or locate faults in an electric iron  Replace a faulty heating element with a good one  Assemble the electric iron and test for its working CIRCUIT DIAGRAM Fig 1 Fig 2 TOOLS REQUIRED  Test lamp 100 W - 1 No.  Screwdriver 150 mm - 1 No.  Spanner D.E. 6mm to 22mm - 1 set  Megger 500V - 1 No.
  • 108.
    102 EQUIPMENT/MACHINES  Electric irons(of different makes) - 3 Nos. MATERIALS REQUIRED Nichrome heating elements for electric irons - 3 Nos. (One for each make of the iron suitable to the iron under test) PROCEDURE AND OBSERVATIONS 1. Record the name-plate details of the given iron. 2. Disconnect the power cord from the electric iron as shown in Fig 1. 3. Read the assemble diagram of the iron. Dismantle the parts. Follow the sequence recommended by the manufacturer. 4. Follow the sequence given below to remove the parts, in the absence of the manufacturer’s recommended sequence of diagram of assembly. Fig 2 5. Remove the asbestos sheet and clean the pressure plate. 6. Obtain a suitable heating element after checking shape, wattage and voltage. 7. Check the new element for its continuity using an ohmmeter/test lamp. 8. Replace with the new element. Assemble the input including connection of the element. 9. Measure the insulation resistance of the element of the iron between the body and the terminals before and after connecting the cord. 10. Test the electric iron with supply for its working. 11. Replace the heating element for two different makes following steps 1 to 10. SAFETY PRECAUTIONS Ensure that the extension from the element is insulated (with mica or asbestos) properly. It is recommended to remove the asbestos sheet and replace with a suitable new one.
  • 109.
    103 NAME OF THEEXPERIMENT Repair and rectify faults in an automatic electric iron LEARNING OBJECTIVES At the end of this exercise the aspirant should be able to  Connect and test the given domestic appliance (automatic iron) for its working  Dismantle the automatic iron and reassemble it  Trace and identify (or) locate faults in an automatic iron  Replace the faulty parts with good ones CIRCUIT DIAGRAM Fig 1 Fig 3 Fig 2 Fig 4
  • 110.
    104 TOOLS REQUIRED  Multimeter - 1 no.  Test lamp 60 W, 240 V - 1 no.  Screwdriver 150 mm - 1 no.  Spanner set 6 to 22 mm - 1 set  Megger 500 V - 1 no. EQUIPMENT/MACHINE  750 W, 250 V automatic electric iron - 1 no. MATERIALS REQUIRED  750 W, 250 V heating element - 1 no.  Thermostat control device - 1 no.  Insulating materials such as asbestos and mica sheets suitable for that iron - 1 no. PROCEDURE AND OBSERVATION 1. Conduct a visual examination of the power cord and plug. 2. Conduct preliminary tests o Cord, for continuity & insulation o Iron, earth fault o Iron, defective element circuit 3. Replace the cord if necessary. 4. Check for the insulation resistance between line terminal of the iron and the body of the iron (Fig 1) and record in Table 1. 5. Check for insulation resistance between the neutral connector and earth. 6. Connect the iron to the mains and check for its working. 7. Check the presence of dangerous voltage existing between the body and earth of the supply with a neon tester or voltmeter. In case of earth fault 8. Disconnect the iron from the supply, dismantle it. Visually inspect and test with a multi-meter/Megger for any contact of live wire with the body. o Insulation failure o Broken parts o Damaged thermostat/actuating leaf porcelain o Switch actuator 9. Rectify the fault by replacing the defective part (element, thermostat etc.). In case of open in element circuit 10. Remove the cover to check the thermostat, indicator bulb circuit and element o Connect the series test lamp to the element circuit shorting the contacts of the thermostat indicated by 1 in Fig 3. If the test lamp glows, the thermostat is defective. o Connect the terminals of the indicating bulb by a piece of insulating wire, shown by 2 in Fig 3. If the test lamp glows the trouble is in this section.
  • 111.
    105 o Short theterminals of the element shown by 3 in Fig 3. If the lamp glows the element is open. Replace the element. Failure of temperature setting controller 11. Check the adjusting knob for proper fixing and actuation of shaft (Fig 4). 12. Open the contacts of the thermostat and inspect them visually. 13. Clean the pitted or burnt out contacts, if reusable. 14. Check for the actuating mechanism. (Heat the thermostat by a suitable external heating device.). 15. Assemble the iron and test for safe working. SAFETY PRECAUTIONS Always disconnect the iron from supply while testing with insulation tester/megger
  • 112.
    106 NAME OF THEEXPERIMENT Service and repair a wet grinder LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Read and interpret data of a wet grinder (R)  Test the line cord for continuity (R)  Measure the insulation resistance between the terminals (R)  Trace, identify and locate faults in a wet grinder (R)  Replace faulty parts with good ones/rectified ones (R) CIRCUIT DIAGRAM Fig 2 Fig 1 Fig 3 TOOLS REQUIRED  Electrician’s tool kit - 1 no.  Test lamp 40W, 240 V - 1 no.  Spanner set of 8 nos. 6mm to 22 mm - 1 no.  Pulley puller 3 leg 200mm - 1 no. EQUIPMENT/MACHINES o Wet grinder (ordinary) (0.25 HP, 230V, 50Hz) - 1 no.
  • 113.
    107 PROCEDURE AND OBSERVATIONS Task1: Servicing of a grinder 1. Switch on the grinder and check for its functioning. 2. Isolate the grinder from the supply. 3. Open the inspection cover. Note down the name plate details in Table 1. 4. Conduct visual inspection: o For supply cord o For good condition of switches o For proper mounting of motor and drive alignment (Fig 1) 5. Conduct an insulation test of the motor and record in Table 2. If the insulation value is above 1 megohm, switch on the grinder and observe its function. 6. If the insulation resistance is less than 0.5 megohm, improve the insulation value by heating or varnishing, provided the motor is opened for varnishing. 7. Clean thoroughly the motor and the bearing of the grinder. 8. Lubricate the bearing as recommended by the manufacturer before assembly. 9. Assemble the motor and tighten the terminal screws, pulley screws, flywheel nuts, motor fixing bolts etc. (after adjusting belt tension) 10. Connect the motor to the supply and start the grinder. Observe the working of the motor and the grinder for smooth running. Task 2: Repairing of grinder Listen to the complaints of the customer/user complaints may be: 1. Grinder not working 2. Fails to start but runs in either direction, when started manually 3. Starts but heats rapidly 4. Reduction in speed – motor gets too hot 5. Grinder is noisy 6. Grinder gives shock Grinder not working  Check whether there is open connection in line. Rectify the fault if observed.  Check for any open circuit in motor winding (starting and running winding). Send it for repairs, if open circuited. Fig 2  Check tightness of the belt. Adjust the belt for proper tension as recommended by the manufacturer. Fig 1  Check whether it is due to tight bearings. Test by turning the shaft by hand. If lubrication does not help the bearing must be replaced.  Check the contact of the centrifugal switch. If the contact of the centrifugal switch is not closed, repair it or replace it. Fig 3  Check the capacitor. Replace it if it is defective. Starts but heats rapidly  Check the centrifugal switch. If it is not opening, rectify or replace. Reduction in speed – motor gets too hot  Check the winding for its short circuit and grounding (earthing).  Check the bearing to know whether it is sticky or to repair or replace, if found defective.
  • 114.
    108 Grinder is noisy Check for worn out bearings – replace the bearings and inspect the shaft for scoring.  Check the end play, add additional end of preventing washers, if the play is too much  Check the loose parts (that is loose hold-down bolts, loose fan, pulleys etc). Tighten them.  Check whether there is misalignment. Align the pulleys correctly. Fig 1  Check the belt. Replace if it is worn out. Fig 1  Check the shaft of the motor. Replace or send the motor for repair, if found bent. SAFETY PRECAUTIONS Grinder gives shock:  Open the inspection cover and check for any line contact with the metallic body. Also ensure earthing is proper  Rectify the accidental contact, if any and insulate item properly.
  • 115.
    109 NAME OF THEEXPERIMENT Service and repair of Geyser LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Read and interpret data of a geyser  Test the line cord for continuity (R)  Measure the insulation resistance between the terminals and the body of the geyser(R)  Dismantle a geyser (R)  Trace, identify and locate faults in a geyser  Replace faulty parts with good ones  Assemble a geyser and test for its working  Test the thermostat for continuity CIRCUIT DIAGRAM Fig 1 TOOLS REQUIRED  Megger 500V - 1 no.  Test lamp 60W, 240V - 1 no.  Line tester - 1 no.  Spanner set (6 to 22mm) - 1 no.  Thermostat 0 – 150 0 C - 1 no.
  • 116.
    110 EQUIPMENT/MACHINES  Geyser (1500watts) 25 litres - 1 no. MATERIALS REQUIRED  Geyser heating element 1500W, 230V - 1 no.  Geyser thermostat - 1 no.  3-core flexible cord (48/0.2) with15A 3-pin plug - 1 no. PROCEDURE AND OBSERVATIONS Task 1: Servicing geysers 1. Record the details of the application in Table 1 2. Open the inspection cover for electrical terminals connection and thermostat installation in the geyser after removing the power plug. 3. Conduct a visual examination of the i) power cord ii) plug pin termination and iii) termination at appliance. 4. Check for proper tightness and good electrical contact at terminations. Replace the plug pin if found petted. 5. Conduct the insulation test on the cord – between the leads, lead and earth. Enter in Table 1. 6. Measure the insulation resistance between the element and the earth/body and the resistance should be 0.5 megohm. If it is less than 0.5 megohm, send the geyser for repair and rectification. 7. Connect the geyser to the supply and switch on the appliance, keeping the inspection/bottom cover of the electrical connections open. 8. Observe that the heating process is cut off by the actuation of the thermostat. The time depends on the capacity of the geyser and the thermostat setting. 9. Switch off the supply. Remove the plug. Measure insulation resistance value between the terminals and the body of the heater/the thermostat while it is hot and record the value in Table 1. 10. Replace the thermostat hot unit if the insulation value is less than one megohm. 11. Refit the inspection cover. It the insulation value is normal (i.e. above one megohm_ apply grease over the screws before fitting. Task 2: Repairing geysers Listen to the complaints of the customer/user and not them. Proceed as stated below for the specific nature of fault/complaint. Nature of fault: 1. No hot water: Check for the undermentioned causes in the given sequence. a) No power b) Defective thermostat c) Thermostat out of calibration d) Defective heater element i) No power 1. Check the fuse of the circuit; replace the fuse, if blown. 2. Check the availability of power at the socket outlet using a test lamp
  • 117.
    111 3. Open theinspection cover and check the cord for its continuity. Replace the cord if necessary. ii) Defective thermostat 1. Check the thermostat for continuity between its terminals at different settings. Replace the defective thermostat with a good one. No continuity between the terminals indicates defectiveness. iii) Thermostat cut off calibration 1. Adjust the thermostat for a higher setting. If the thermostat is found to be good, switch ON supply. Observe the fuse. iv) Defective element 1. Check the element for its continuity and insulation value between the terminal and the body (sheathing of the element). 2. Replace the defective heating element with an identical good one. Switch on the supply and observe. 2. Water too hot: Check for the undermentioned causes a) Thermostat set too high b) Defective thermostat i. Check the setting of the thermostat and adjust it to a lower value. Switch on the geyser. Wait for the thermostat to cut off the supply of for about 20 minutes. Open the inlet. Collect the water at the outlet and measure the hot water temperature. ii. If the water temperature is much higher than the set value of the thermostat, replace the thermostat with a good one. If the temperature of the hot water is close to the range setting of thermostat it indicates a defective setting as the only cause. 3. Water not hot enough: check for the undermentioned causes a) Thermostat set too low b) Incorrect heater element c) Excessive lime in tank i. Check the thermostat setting and adjust it to a higher value. If the geyser produces hot water with the resetting, then the earlier setting was wrong. ii. Check and test the wattage of the heating element. If it shows a lower value, replace it with a higher wattage element. iii. Remove the heating element; inspect the element and the inner side of the copper vessel for deposit of excess lime coating. In case the heating element is of correct wattage and the thermostat is properly set, remove the lime coating. SAFETY AND PRECAUTIONS 1. Drain the water from the container of the geyser before removing the element. 2. Switch off the supply and remove the plug before opening the cover. 3. The geyser should be switched on only with water in the container. 4. Check and ensure that the switch is off before removing the power plug.
  • 118.
    112 NAME OF THEEXERCISE Repair and service of a table fan LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Test the given table fan for its working  Dismantle the table fan  Trace and identify or locate faults in the table fan  Replace faulty parts with good ones  Test the capacitors  Clean and lubricate the bearings  Check the oscillation mechanism  Check the speed regulator  Reassemble the table fan and test for its working. CIRCUIT DIAGRAM Fig to be added TOOLS REQUIRED  D.E spanner set 6 to 22 mm - 1 no.  Cutting pliers 150mm - 1 no.  Screwdriver 150mm - 1 no.  Soldering iron 65W, 230V - 1 no. EQUIPMENT/MACHINES  Table fans (one each of three different sizes) - 3 nos. MATERIALS REQUIRED  Connecting cables - as reqd.  Grease - as reqd.  Three-in-one oil / SAE 30 - as reqd.  Solder resin – cored - as reqd.  Insulation tape - as reqd. PROCEDURE AND OBSERVATION Task 1: Servicing of a table fan 1. Switch ON the fan and check for its function, at different settings of the speed regulator and oscillation mechanism. Observe and record the condition. Disconnect the fan from the supply 2. Conduct visual inspection on the  Main cord insulation  Plug pin termination for tightness and goodness electrical contact. 3. Set right the defects, if any is noticed. 4. Remove the front guard and blade assembly and clean them. Fig 1 5. Place the fan in a lying position on a pad or cloth.
  • 119.
    113 Take care thatthe guard is not damaged 6. Open the bottom cover and clean the dust and dirt with a brush. 7. Disconnect the main cord. 8. Conduct the insulation test on the main cord and record the values. Replace it if the value of insulation resistance is less than 1 megohm. 9. Measure the insulation resistance of the fan windings and record it. Replace it if the value is less than 1 megohm. 10. Clean the regulator contacts. Reconnect the main cord. (Fig 1) Refix the bottom cover and keep the fan in normal position. 11. Remove the oscillating gear assembly. Clean and lubricate with fresh grease. 12. Lubricate the bush bearings with SAE 30 oil. (Fig 1) Fix the oscillation gear box in position. 13. Refix the blade and guard assembly. Switch ON the fan for its working. Task 2: Repairing of a table fan Listen to the user’s complaints. The complaints may be any one or a combination of the following. a) Fan is not running b) Noisy c) Not oscillating d) Fan produces humming noise e) Bearings of the oscillating mechanism rattle f) Oscillating mechanism is noisy A. Fan is not running. 1. Check the socket outlet for the availability of supply 2. Remove the bottom inspection cover 3. Check the continuity of the power cord 4. Check the regulator switch assembly. (Fig 1) Rectify if any faulty is observed. 5. Ensure free rotation of the fan with your hand. Find the cause and rectify if it is too tight (bearing assembly, foreign body etc.) 6. Check the capacitor. Replace if defective. (Fig 1) rectify loose connections if any. 7. Check the winding for continuity and insulation. (Fig 2) Send it for rewinding, if necessary. B. Fan is noisy 1. Collect the history and nature if the noise of the fan from the user. 2. Run the fan and observe the noise. 3. Identify the noise and find out if the noise is due to one or the combination of the following. o Loose element of the blade o Loose or missing screws o Lack of lubrication or dirt in bearing o Worn our bush o Blade distortion/breakage (fig 3) o Alignment of blades o Loosely fitted gaurds
  • 120.
    114 C. Fan notoscillating 1. Check the compression stud, worm gear and pinion. 2. Check the gear for broken teeth 3. Check for a bent rotor shaft 4. Check the gear pin for proper setting. If it is loose, either knurl the end slightly and press it into place or replace the complete gear assembly. D. Fan produces humming noise 1. Check the air gap for unevenness. If it is incorrect check the correct fitting of the end shields as per the markings. 2. Check armature for a bent shaft 3. Check for worn out or loose bearing fit. If bearings are defective, replace them. When replacing, clean the washers and rotor shaft should be lubricated with a light film of SAE-30 motor oil. E. Bearings of the oscillating mechanism rattle 1. Check for worn out bearings, particularly at the fan blade side. 2. Check the rotor for excessive wear 3. Check for proper grease. Clean out the gear case and replace with the grease recommended in the service manual. F. Oscillating mechanism is noisy 1. Excessive end play between the compression stud and the cover may be the cause of this noise. To prevent excessive end play, use spacers between the compression stud and worm gear.
  • 121.
    115 NAME OF THEEXPERIMENT Servicing and repairing of food mixer LEARNING OBJECTIVES At the end of this exercise you shall be able to  Read the interpret the data of the given food mixer.  Indentify the area of problem in the food mixer by visual inspection and tests.  Dismantle the food mixer.  Trace, identify and locate faults in the food mixer.  Replace faulty parts with good ones.  Clean and lubricate the bearings.  Assemble the food mixer and test for its working. REQUIREMENTS 01. Screwdriver set of three 1 No. 02. Test lamp 100 W, 240 V 1 No. 03. D.E. spanner set of six 6 mm to 22 mm 1 set 04. Plastic spanner for opening the jar screw 1 No. 05. Box spanner set of 6 mm to 22 mm 1 Set 06. Multimeter 1 No. 07. Megger 500 V 1 No. 08. Philips screwdriver 4 mm blade dia. 1 No. Equipment/ Machines 01. Food mixer 240 V 50 Hz. 400 Watts 1 No. Materials 01. Grease / lubricating oil as reqd. 02. Kerosene as reqd. 03. Cleaning brush 1 No. 04. Sandpaper smooth as reqd. 05. Soldering lead, 40:60, soldering flux as reqd. 06. Service manual (if available) 1 No. PROCEDURE Task 1: Servicing of a mixer 01. Note down the name plate details in the maintenance card. (Table 1) 02. Enter the details of the complaint from the customer in the maintenance card. 03. Switch on the mixer and check for its functioning. 04. Isolate the mixer from the supply. 05. Open the bottom cover and conduct visual inspection for:  Damages in the supply cord and loose terminal connections  Good condition of switches.  Proper mounting of the motor. 06. Check whether the nylon / rubber coupling of the jar and motor are properly seated, if not replace. Sometimes the retaining spring and washer might have got spolled and need to be replaced.
  • 122.
    116 TABLE 1 MAINTENANCE CARD 07.Remove the insulation value by heating or varnish if the insulation value is less than one megohm enter test results in the maintenance card. (Table 2) 08. The motor is opened for varnishing, clean thoroughly stator and armature and bush bearings. (Fig 2) 09. Conduct the insulation test after varnishing and enter results in the maintenance card (Table 2). Remember that the nuts at the blades and the centre shaft holding nut are to be loosened by clockwise movement and tightened by anti – clockwise movement in the most of the mixers. 10. Lubricate the bearing as recommended by the manufacture before assembly. Most of the bearings need no lubrication. If required, a drop of light oil like 3 – in – 1 oil could be used. 11. Clean the commutator surface. A black carbon deposit could be removed by CTC. Seat the bushes properly over the commutator. Check for adequate length of brushes to exert spring pressure. If the brush length is shorter by 1 / 3 of its original length it is better to replace with the brushes of the same grade and size. The new brush has to be bedded in the commutator properly. 12. Assemble the motor and tighten the terminal screws. 13. Assemble the blade with the jar and nylon coupling at the bottom. 14. Connect the motor to the supply and start the mixer. 15. Observe the working of the mixer for smooth running. TABLE 2 Date of Servicing Insulation resistance before varnishing / heating Insulation resistance after varnishing / heating Details for repair and replacement Between terminal and body Between armature and field Between terminal and body Between armature and field Name of the Customer … ... … … …. Address … ... … … …. Name of the appliance … ... … … …. Serial No. … ... … … …. Wattage … ... … … …. Current… ... … … …. Voltage… ... … … …. Supply … ... … … … … … … … … Make… ... … … …. … Date of Servicing Customer’s Complaint Defect Noticed by visual inspection Details of repair and replacement
  • 123.
    117 Task 2: Repairingof mixer Listen to the complaints of the customer / user and other in the maintenance card (Table 1) 01. Common complaints are listed in the troubleshooting along with reason for the possible cause and the active action to be taken. 02. Inspect visually the following parts for trouble.  Power cord and plug  Terminal connections at the switch (back cover to be opened)  Couplings  Freeness of the shaft  Burnt smell or discolouring of windings 03. Conduct the continuity and insulation tests and enter the values in Table 2. Ascertain the area of problem by analyzing the customer’s complaint, visual inspection and test results. (Refer to the maintenance card.) 04. Troubleshoot the mixer following the hints given in the troubleshooting chart. 05. After assembling the mixer conduct the continuity and insulation test. Enter the values in the maintenance cards given earlier. 06. After satisfactory values of the test are obtained connect the mixer to the supply, and test run. TROUBLE SHOOTING CHART Problem Possible Cause Corrective Action Mixer does not run a. Overload trip might have tripped. b. No power at the outlet c. Defective power cord or plug. d. Locked shaft. e. Worm out brushes. f. Open circuited. a. Reset the overload relay and advice the customer not to overload the mixer in the future. b. If the mixer is running in your shop but not running at the customer’s house ask the customer to get the socket repaired. c. Test, repair or replace the power cord / plug. d. Unplug the supply and try to rotate the shaft by hand. Clean the bearings; lubricate the bearings as advised by the manufacturer. If the shaft is still tight, replace it with suitable bearings. The shaft might have got bent. Replace the shaft or armature assembly. e. Replace the brushes and loose springs. f. Check the field and armature windings if found defective get it rewound. Blows fuse when switched on a. Shorted power cord. b. Locked shaft. a. Replace the cord. b. As in ‘d’ above.
  • 124.
    118 c. Defective armatureor field coils d. Poor insulation resistance. e. Low capacity fuse. c. Test the windings for short, if short is found rewind. d. Check, test and repair. e. Check the capacity of the fuse against the mixer rating. Erratic operation and speed. a. Defective cord. b. Loose connection at socket or plug or at switch terminals. c. Poor spring tension or worn out brushes. d. Defective switch a. Check the cord for intermittent break. Repair or replace. b. Check and tighten the connections. c. Check, repair or replace. d. Replace the switch. Slow speed with break power a. Wrong material or too much quantity loaded for mixing. b. Jammed rotor. c. Tight blade assembly d. Worn out brushes or loose spring. e. Bent shaft. f. Partially shorted or grounded winding or poor insulation resistance a. Verify from the customer about the load and advise accordingly. b. Rotate by hand. If found tight, clean the bearing and lubricate it. If it is found still tight, change the bearings or check for bent shaft. c. Check the spring, washer and assembly. Repair or replace. d. Check, repair or replace. e. Check, repair or replace f. Check, test and repair / rewind. Mixer runs but becomes hot a. Overloading of mixer. b. Time rating of mixer is exceeded. c. Bent shaft and rotor is rubbing the stator. d. Improper coupling. a. Bring down the load in the mixer or advise the customer to go for a higher capacity mixer. b. Check the duration the mixer is switched on by the customer and compare with the mizedr rating. Advise accordingly. c. Check, repair or replace. d. Check, repair or replace. e. Check, test and rewind.
  • 125.
    119 e. shorted winding. Mixeris noisy a. Dry bearing. b. Loose mounting screws. c. Rotor rubbing against stator. d. Bent fan blades. e. Broken or missing gasket. a. Check and lubricate. b. Check and tighten the loose screws. c. Check the alignment and shaft for bend. Repair or replace the shaft. d. Check and straighten the blades. If not possible replace the fan blades. e. Replace Motor runs on one speed only a. Check the speed selector switch connections and function of switch b. Partially burnt out field winding. a. Repair or replace the switch b. Test with multimeter. Repair or rewind. Bad sparking at motor brushes a. Struck or worn out or loose brushes b. Pittings or uneven commutator surface. a. Check, reshape the brushes, replace the springs or reposition the brushes for proper tension. b. Use sandpaper or turn the commutator on a lathe. Mixer produces shock a. Water leaking and coming in contact with live terminals. (Double insulated misers with plastic body and two pin plug. No earth connection) b. Vent hole in the mixer body clogged. c. Damaged power cord. d. Absence of earth connection. e. Live parts coming in contact with metal body. a. Check the drain hole in the coupler head assembly for blockage. Check the jar examination for leakage due to lose shaft or worn out bearing, ebonite washer breakage. Repair or replace. b. Clean the vent hole. c. Check and replace. d. Check the earth connection in the mixer motor, power cord and at socket. Repair and re do the earth connection. e. Check, repair and in contract with recheck with a megger. Smoke coming from coupling a. Improper seating between couplings. a. Check whether male and female parts of the coupling are properly seated. If not check the assembly. Include additional washers in the detachable blade assembly to make proper seating between couplings. b. Check and change the coupling.
  • 126.
    120 b. Worn outcoupling. c. Misaligned coupling. c. Check the motor assembly and align.
  • 127.
    121 NAME OF THEEXPERIMENT Assembling and repair of electric kettle LEARNING OBJECTIVES At the end of this exercise the aspirant will be able to  Assemble electric kettle  Repair the electric kettle  Understand the function of emersion rod  Repair emersion rod TOOLS REQUIRED  Heating element  Screwdriver EQUIPMENT/MACHINE  Emersion rod MATERIALS REQUIRED  Nuts  Emersion rod of 500W, 750W and 1000W  Asbestos sheet  Washer, bolts, wires  Thermostat switch PROCEDURE AND OBSERVATION 1. A stainless steel kettle is taken 2. Emersion rod (heating element) is fixed inside the kettle with the help of nut. Washer is also fixed to prevent leakage of water. 3. Lead is connected flow of electric current 4. A round size of asbestos sheet is kept over the heating element SAFETY PRECAUTION Washer should be tightly fitted with the nut to avoid the leakage of air and water, otherwise heating element will be fused.
  • 128.
    Assam Nagaland Manipur Mizoram Tripura Arunachal Pradesh Nagaland Manipur Mizoram Tripura ArunachalPradesh Sikkim Nepal Jammu and Kashmir Himachal Pradesh Punjab Haryana Rajasthan Gujrat Madhya Pradesh K e r a l a Goa Goa Andhra Pradesh Orissa West Bengal Jharkhand Uttar Pradesh Delhi Chattisgarh Meghalaya Bihar Tamil Nadu Karnataka Maharastra Andhra Pradesh Orissa West Bengal Jharkhand Uttar Pradesh Chattisgarh Meghalaya Bihar Tamil Nadu Karnataka Maharastra Chennai (2) Bangalore (2) Jumaikella Hyderabad (2) Chinchwad Delhi (2) Lucknow Bhubaneswar Ranchi Kolkata Shillong Patna Purnea Brahmapur Rajam Vijayawada Madurai Tirunelveli Kanyakumari Uttarakhand Thank You For further information please contact us: in.seif.etp@in.schneider-electric.com www.schneider-electric.co.in