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 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.

3. 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.

4. 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

5. 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

6. 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

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
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.

9. 3

10. 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:

11. 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)

12. 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

13. 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

14. 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

15. 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.

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 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

18. 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)

19. 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

20. 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)

21. 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

22. 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

23. 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

24. 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

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 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

27. 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)

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, 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

30. 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

31. 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%

32. 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

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
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

35. 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

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 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.

38. 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

39. 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

40. 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

41. 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

42. 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

43. 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

44. 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.

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 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.

49. 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

50. 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.

51. 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.

52. 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
-
-
-
-
-

53. 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

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 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.

56. 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.

57. 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

58. 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.

59. 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.

60. 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

61. 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

62. 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

63. 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)

64. 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

65. 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)

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 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

68. 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.

69. 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.

70. 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.

71. 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.

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 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.

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 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.

76. 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.

77. 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.

78. 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.