Workshop

Practice I

Lecture Note

22/11/2024
 Course outline
1. General Safety
2. Common types of Electrical
Hand Tools
3. Splicing and Joining of wires
4. Termination
5. Soldering
6. Wiring materials and
accessories
7. Electrical wiring circuits
8. Industrial installation
 Chapter One
Health & Safety - Electricity at Work
❑ Electrical Safety
❑ Before starting any installation work, the first and foremost
thing is the concern of safety of the personnel.
❑ Electricity is dangerous and direct or indirect contact of
electrical equipment or wires with the power turned ON can
result in serious injuries or sometimes even causes death.
❑ Workplace hazardous systems are designed to protect the health
and safety of workers.
❑ Information must be provided about the safe handling,
usage, storage and disposal of hazardous systems.

’’Electricity is a good servant but a bad master’’

 1.1 Electrical Accidents
❖ Accidents at work involving electric shock or burns
❖ Can lead to fires which may also cause death or injury to others
❖ Over-hating and malfunction of electrical devices
Causes
⮚ Involves portable equipment's
⮚ Poor electrical installations
⮚ Faulty electrical appliances
Solutions
❑ Careful planning and straight
forward precautions
❑ Identify the hazard and reduce
the risk of the hazard occurring
❑ Majority of the hazards can be avoided by being aware and taking
appropriate precautions
 1.2 Workshop Safety
∙ Safety in the workshops is subject to a number of various risk
assessments and safe codes of working practices which have to be
observed and adhered to by all workshop users
∙ Workshops access to these areas is restricted to authorized personnel
only
∙ No other person may enter the workshops without permission
1.2.1 Workshop Equipment and Tools Safety rule
a. No machine may be used or work undertaken unless the technician-
in-charge is satisfied that the person is capable of doing so safely
b. Any person working in the mechanical and electronic workshop
must have read and signed the appropriate risk assessment
c. Service records of all machine tools, plant and equipment must be
kept
 1.2.1 Workshop Equipment
and Tools Safety rule
d. All Portable Electrical Equipment must be regularly inspected and
tested for electrical safety
e. Suitable Local Exhaust Ventilation (LEV) must be used
f. Ladders/stepladders should be individually identified and formal
inspections carried out
g. Equipment must be cleaned after use. Any materials, tools or
equipment used must be tidied away
h. Precision measuring equipment, drills, etc. must be replaced in
their appropriate cabinets after each working day
i. Tools and equipment must not be removed from the workshop
without permission from the technician-in-charge
 1.2.2 Workshop Practices and
Personal Protective Equipment
i. When working with machine tools or other equipment with rotating
spindles, jeweler, loose clothing etc. are prohibited.
ii. Always use Personal Protective Equipment (PPE) like goggles,
gloves, shoes, etc. and avoid any direct contact with live or
energized circuits.
iii. Have the skills and techniques to distinguish the exposed live parts
of the electrical equipment.
iv. Disconnect the source supply while installing or connecting wires.
v. The power supplied to the installation must be controlled on the
main switchboard, which should consist of circuit breaker
vi. Conductive tools and materials must be kept at a safe distance
from live parts of the circuit or equipment.
vii. Lab coats/overalls and safety boots must be worn by technicians
operating the machines
 1.2.2 Workshop Practices and
Personal Protective Equipment
viii. The gangway through the workshop must be kept clear. Any oil
spillage, grease etc. must be cleaned up immediately.
ix. Do not carry loads such that the weight may be dangerous or
vision obscured
x. Eating and drinking in the workshop areas are strictly prohibited.
xi. Avoid water at all times when working with electricity.
xii. If you are repairing an electrical device always turn off the mains
supply

Fig. Personal protection

equipment
 1.3 Fire Extinguisher
❑ A fire extinguisher is a protection device used to cease fire. It is the
basic first aid equipment which can be effectively used for
controlling fire.
❑ A fire extinguisher is a cylindrical pressure vessel containing an
agent which can be discharged to cease a fire.
❑ A fire extinguisher should always be available in areas where
persons work with electrical equipment

Fig. Parts of fire extinguisher

 1.3 Fire Extinguisher
❑ The following steps demonstrate the operation of a fire extinguisher
in case of a fire emergency.
Step 1: Identify the safety pin of the fire extinguisher which is
generally present in its handle
Step 2: Break the seal and pull the safety pin from the handle
Step 3: Use the fire extinguisher by squeezing the lever
Step 4: Sweep it from side to side
 1.4 First Aid for Electrical
Emergencies
❖ Electrical accidents cause countless injuries. Injury could be
minimized and many lives saved if proper rescue techniques and
treatments are used. Electrical accidents may occur at any time or
place. Timely response and treatment of victims is a major concern.
❖ When an electrical accident occurs, due to the effect of muscle
clamping, a victim is often incapable of moving or releasing the
electrical conductor. Caution should be a primary consideration
during any electrical accident or emergency. There should always be
an emergency response plan for scheduled electrical maintenance or
work.
 Chapter Two
Electrical Tools
❑ Combination Pliers : Used for holding, twisting or cutting of wires.

❑ Side cutting Plier: Used for Cutting at narrow places or ordinary

places for removing insulation.
 Electrical Tools
❑ Round Nose Plier or Flat Nose Plier: Used for holding, twisting or
joining the wire at narrow places.

❑ Tenon saw or back Saw: Used for cutting wooden boards, Block
casting etc.
 Electrical Tools
❑ Hack saw: Used for cutting conduit GI pipes or mild steel

❑ Mallet: Used as a hammer and made of wood or plastic

It is also used to reduce the force driving the cutting edge of a chisel,
giving better control.
 Electrical Tools
❑ Electric knife: removing insulation of wires

❑ Line Tester: Used for testing the current.

 Electrical Tools
❑ Screw driver: Used for loosening, tightening and to keep the screws
in position.

❑ Royal Plug Tool: It is made of steel and is used for making holes
in the stone wall or concrete wall for fiber made Royal plugs.
 Electrical Tools
❑ Ball Peen Hammer: Used for fitting nails in the walls or wooden
boards.

❑ Soldering Iron: Used to solder small joint terminals

 Electrical Tools
❑ Crimping tools: are a varied collection of devices used to join
materials or components by pressing them together and creating a
seal or crimp.

❑ A wire stripper: is a portable handheld tool used by workers,

especially electricians, for removing the protective coating of an
electric wire in order to replace or repair the wire
 Chapter Three
Wire Splicing
Introduction
❑ In all jobs of wiring splicing (jointing) and termination is a
necessity.
❑ The jointing is required since the wires are manufactured in 100
meters lengths and may be when more than 100 meters the
termination of wires is needed, to be connected to switches holders
receptacles etc.
❑ It is important to note that all point made must be mechanically and
electrically sound.
 Wire Splicing
Lab 1 Wire splicing
Objective:- to make different types of splicing
Materials:- Solid wire, Pliers side cuter, Insulation remover, and
Electrical knife
 Types of Splices
❑ Here the techniques usually used to splices conductor in electrical
works will be explained as follows.
1) Western Union Splice
✔ The Western Union splice joins small, solid conductors.
Steps to make splice:
a) Prepare the wires for splicing, remove the insulation and clean
the conductor
b) Bring the wires to a crossed position and make a long twist or bend
in each wire
c) Wrap one end of the wire and then the other end four or five times
around the straight portion of each wire
d) Press the ends of the wires down as close as possible to the straight
portion of the wire. This prevents the sharp ends from puncturing
the tape covering that is wrapped over the splice.
Types of Splices
 Types of Splices
2) Staggering Splices
❖ Joining small multi-conductor cables often presents a
problem.
❖ Each conductor must be spliced and taped.
❖ If the splices are directly opposite each other, the overall
size of the joint becomes large and bulky.
❖ A smoother and less bulky joint can be made by staggering
the splices.
Steps:
a) Remove enough insulation from the cables.
b) Remove the insulation of wires in each cable in different
lengths for the wires that are going to be spliced together.
 Types of Splices
c) Splice a short wire from one side of the cable to a long
wire from the other side of the cable.
d) Clamp the sharp ends firmly down on the conductor.
 Types of Splices
3) Rattail Joint
❑A splice that is used in a junction box and for
connecting branch circuits is the rattail joint.
❑Wiring that is installed in buildings is usually
placed inside long lengths of steel or aluminum
pipe called a conduit.
❑Whenever branch or multiple circuits are
needed, junction boxes are used to join the
conduit.
 Types of Splices
Steps to create a rattail joint:
❖ To create a rattail joint, first strip the insulation off the
ends of the conductors to be joined.
❖ Then twist the wires to form the rattail effect. This type
of splice will not stand much stress.
 Types of Splices
4) T-Tap Joint
▪ Used for connecting the end of one wire to the middle of
another wire, thus forming a shape like that of the letter "T“.
▪ The new wire that connects to the main wire is called the
branch wire or tap wire. This is a prevalent junction type used
in knob and tube wiring.
 Types of Splices
5) Knotted Tap Joint
❑ All the splices discussed up to this point are known as
butted splices.
❑ Each was made by joining the free ends of the
conductors together.
❑ Sometimes, however, it is necessary to join a branch
conductor to a continuous wire called the main wire.
Such a junction is called a tap joint.
❑ The main wire, to which the branch wire is to be tapped,
has about 1 inch of insulation removed.
❑ The branch wire is stripped of about 3 inches of
insulation.
 Types of Splices
Steps:
i. Place the branch wire behind the main wire and extend
three-fourths of the bare portion of the branch wire
above the main wire.
ii. Bring the branch wire under the main wire, around
itself and over the main wire to form a knot.
iii. Then wrap the branch wire around the main conductor
in short.
iv. Tight turns; and cutoff the end.
v. The knotted tap is used where the splice is subject to
strain or slippage. When there is no strain, the knot may
be eliminated.
Types of Splices
 Chapter Four
Termination
Termination is the process of connecting the end of a cable, wire,
or electrical component to a connector, device, or terminal block.
❑ It involves attaching a conductor to a terminal, connector, or other
device in order to establish an electrical or mechanical
connection, as well as allowing for easy disconnection when
required.
❑ Termination is an essential aspect of electrical and electronic
systems, as it ensures the proper functioning and safety of the
equipment.
❑ One of the main cause of electrical problems is poor termination.
❑ They can simply result in failure of equipment to function or even
start fire.
❑ The use of an inadequate size and type of cable or cord can also
result fire.
 Termination Basics
❖ There are hundreds of connector styles that come in thousands of
configurations, used for a wide range of applications.
❖ Most connectors and terminations share common traits:
▪ Connectors mate with other connectors
▪ Connections must be mechanically and electrically sound
▪ Connections must meet performance criteria
❖ Genders
▪ Male = Plug = Pin
▪ Female = Jack = Receptacle = Socket
▪ Hermaphroditic (single gender)
✔ Wall outlets are typically female connectors
✔ Connectors on cables are typically male.
 Types of Termination
❑ The type of termination used will depend on the application and
requirements of the system, and involves various techniques such
as crimping, soldering, screwing or compression.
❑ Terminations should be done with proper tools and techniques to
provide a reliable and safe electrical connection.
❑ There are different types of cable terminations depending on the
specific application. Here are some commonly used termination
types:
1. Crimped termination - This type of termination involves
crimping a metal barrel onto the stripped wire and then inserting it
into the connector. It is commonly used in electrical and network
cabling.
 Types of Termination
2. Soldered termination - This type involves applying solder onto
the stripped wire and holding it in place with a connector. It is
commonly used in audio and video cables.
3. Compression termination - This type involves compressing the
connector onto the wire with a special tool. It provides a sturdy
and reliable connection and is commonly used in coaxial cables.

4. Screw type termination - This type of termination involves

securing the wire in place with a screw. It is commonly used in
speaker cables.
 Types of Termination
5. A ring end termination is a type of cable termination
where a ring-shaped terminal is attached to the end of a
wire or cable.
❑ The ring terminal has a hole in the center where it is secured
to a terminal block, stud, screw or other connector.
❑ Ring end terminations are commonly used in electrical and
electronic applications to connect wires to components such
as relays, circuit breakers, transformers, and switches.
❑ They are often used in high voltage or high amperage
applications where a secure and reliable connection is
crucial to ensure the safety and proper functioning of the
system.
 Types of Termination
6. A stub-end termination refers to a type of cable termination that
involves attaching a flange or a plate to the end of a cable or pipe.
❑ The flange or plate is then bolted to a matching flange or plate on a
piece of equipment or piping system.
❑ The purpose of a stub-end termination is to allow for easy
disconnection and connection of a cable or pipe while maintaining
a permanent connection to a piece of equipment or piping system.
❑ This is useful in situations where frequent disconnections of the
cable or pipe are required for maintenance, repair or replacement.
❑ Stub-end terminations are commonly used in piping systems in the
chemical, petrochemical, and oil and gas industries.
❑ They are also used in water and wastewater treatment facilities.
 Types of Termination
7. A lug-end termination is a type of cable termination
where a lug or a connector is attached to the end of a cable.
The lug or connector is then attached to a terminal block,
switch, or other electrical equipment using a bolt or screw.
❑ Lug-end terminations are commonly used in electrical and
electronic applications for connecting cables to power
sources, motors, generators, transformers, batteries, and
other electrical equipment.
❑ They are especially useful in high-amperage or high-voltage
applications where a secure and reliable connection is
essential for safety and proper functioning of the system.
 Criteria for Good Terminations
❑ Every cable termination should be completed and checked using the
following headings.
❖ Solid Conductors – doubled back where possible.
❖ Stranded and Flexible Conductors – all strands twisted neatly together in
the right direction, and doubled back where possible. – all strands present
and clamped.
❖ No damage to conductor e.g. nicked while stripping insulation.
❖ No damage to insulation e.g. nicked while stripping sheath or pulling in
cables.
❖ Insulation not clamped.
❖ Conductor insulated right up to the metal of the terminal (no bare copper )
❖ Sufficient slack available on cable.
❖ Cable arranged neatly and not fouling moving parts or covers.
❖ No makeshift terminals used.
❖ Terminal screw tightened sufficiently.
 Poor electrical terminations

❑ Loose connections give rise to heat.

❑ This heat travels from its point of origin, along the
conductor in both directions.
❑ The insulation becomes brittle, delicate and disintegrates.
❑ The result is a high resistance joint.
❑ Possible damage to equipment.
❑ Possible electric shock.
❑ Possible fire hazard.
 Chapter Five
Soldering
5.1 Introduction
⮚ Soldering is defined as "the joining of metals by a fusion
of alloys which have relatively low melting points".
⮚ It is a must have skill for all sorts of electrical and
electronics work.
⮚ It is also a skill that must be taught correctly and developed
with practice.
Most common types of soldering required
✔ For electronics work.
✔ Soldering components to printed circuit boards and
✔ Soldering a spliced wire joint.
 5.2 Soldering Equipment
❑ The Soldering Iron
▪ The first thing you will need is a soldering iron, which is
the heat source used to melt solder.
▪ Irons of the 15W to 30W range are good for most
electronics/printed circuit board work.
▪ Anything higher in wattage and you risk damaging either
the component or the board.
❑ Soldering guns
▪ to solder heavy components and thick wire
▪ familiar gun shape with a large high wattage tip heated by
flowing electrical current directly through it.
5.2 Soldering Equipment
Silver solder
 Solder Selection

❑ The choice of solder is also important.

❑ There several kinds of solder available but only a few
are suitable for electronics work.
❑ Most importantly, electronic circuit use rosin core
solder.
❑ Acid core solder is common in hardware stores and
home improvement stores, but meant for soldering
copper plumbing pipes and not electronic circuit.
❑ If acid core solder is used on electronics, the acid will
destroy the traces on the printed circuit board and
erode the component leads.
 A step to make Soldering

1. Prepare a work space. Lay down a mat or piece of

cardboard that will catch any solder that you drip.
2. Warm your soldering iron. If your soldering iron is
electric, you’ll need to allow it to warm up on its stand. If
your soldering iron runs on butane, as Master Appliance
soldering irons do, fill it with gas holding the unit firmly
with the refill nozzle pointed upwards and press down. Gas
will overflow from nozzle when tank is full.
3. Secure the items you are soldering. It helps to have an
extra hand while you are soldering. We suggest using a
vise or frame to secure your work.
 A step to make Soldering

4. Clean your soldering iron. Because soldering irons get so

hot, they oxidize and become dirty quickly. They key to
reliable connections is clean components so make sure that
your soldering tip and parts you are joining are clean. To
accomplish this, pass the tip of your soldering iron on a
wet sponge until it shines.
5. Apply flux. In soldering it often becomes necessary to use
materials called fluxes to help remove oxides and keep
them absent while you solder. Flux needs to melt at a
temperature lower than solder so that it can do its job prior
to the soldering action. There are different methods to
apply flux. The method you choose will be dependent on
 A step to make Soldering

6. Tin your soldering iron. Tinning is the process of coating

a soldering tip with a thin coat of solder. Melt a thin layer
of solder on your iron’s tip. This aids in heat transfer
between the tip and the component you are soldering, and
also gives the solder a base from which to flow from. This
process may need to be repeated as you solder. You will
only touch the tip of the soldering iron to the solder when
you tin. Do not touch the tip of the iron to the solder while
you are actually soldering.
7. Start soldering. Hold the soldering iron like you would a
pen in the hand you write with and the solder in the other.
 A step to make Soldering

8. Place the tip of the soldering iron tip. The tip needs to
touch both the wire lead and the surface so they achieve
the same temperature.
9. Feed solder onto the joint after you have heated the
area for two to three seconds. Touch the solder to the
side of the connection opposite the soldering iron. Then,
let the solder flow only until the connection is covered.
10. Remove the solder first. Then, remove the iron. Make
sure the joint remains stationary while it cools.
11. Evaluate. A smooth, shiny and volcano shaped joint is
what you are looking for. If this isn’t what you see, you’ll
need to reheat and feed in more solder.
 A step to make Soldering
Warnings
▪ DO NOT lay a soldering iron down on any surface. A soldering
iron should either be placed on a stand or sealed with a heat
resistant cap after every use. Note: Master Appliance's line of
soldering irons is butane powered. All of our irons come with heat
protective caps.
▪ Soldering should be completed in a well ventilated area.
▪ Lead is present in most solders. Be sure to wash your hands after
your project, or better yet wear gloves.
▪ The tip of a soldering iron is very hot. Contact with the tip of a
soldering iron would result in a nasty burn.
▪ Your soldering iron will perform better if kept clean. A damp
sponge can be used to clean residue caused by flux material. A
very small skim of flux should be applied to the iron after the
 Chapter Six
Wiring Materials and Accessories
Residential Installation
In order to assemble properly and intelligently the great
number of available electrical materials, devices, fittings,
and equipment to form a complete wiring system, we must
understand the basic principles regarding them. These are:-
❖ Wire and Cables
❖ Conductor materials used in cables
❖ Insulating materials
❖ Conduit accessories and fittings
❖ Lighting accessories and fittings
❖ Fuses and circuit breakers
❖ Distribution board
 Wire and Cables
▪ In practice bare conductors, whether single or stranded
together are termed as wire and conductors covered with
insulation are termed as cables.
▪ The necessary requirements of a cable are that it should
conduct electricity efficiently, cheaply, and safely.
✔ A cable consists of three parts:
A. The conductor or core: the metal wire or strand of
wires caring current.
B. The insulation(dielectric): a covering of insulation
material to avoid leakage current from the conductor.
C. The protective covering: for protection of insulation
from mechanical damage.
 Wire and Cables

Electrical wire is made of materials like copper, aluminium and

silver. As silver is expensive, mostly copper and aluminium are used
in wiring.
Materials are classified into three types according to their
properties:
❑ Conducting materials
❑ Insulating materials
❑ Semiconductor materials
 Conductor materials used in
cables
1. Copper:
▪ Is best conductor next to silver, which is comparatively
cheap.
▪ It is mechanically strong, extremely tough, durable,
ductile, it is highly resistive to corrosion.
▪ It is used in wiring materials in cables.
▪ Its has low resistance and is used
▪ for conduction of electricity at high, medium and low
voltage
2. Aluminum:
▪ is frequently used for long distance power distribution.
▪ Has an electrical conductivity of 60% of copper.
▪ It is light weight and cheaper in comparison to copper.
 Insulating Materials
⮚ it must possess the following properties.
❖ High resistivity
❖ High flexibility
❖ Non-in flammability
⮚ Various types of insulating materials used in cables are:
1. Rubber:
✔ Though it posses high insulating qualities, it absorbs moisture,
softens when heated to a temperature of 60 to 70, swells under the
action of mineral oils and ages when exposed to light.
✔ Hence pure rubber cannot be used as insulating materials.
2. PVC(polyvinyl chloride): is a man made thermo-plastic
materials, which is tough, incombustible , chemically uncreative,
does not deteriorate with age.
✔ Its chief drawback is that it softens at a temperature above 80.
 Insulating Materials
3. Vulcanized Indian Rubber:
⮚ It is prepared by mixing Indian rubber with sulphur, zinc, red lead,
etc.
⮚ It absorbs water, which reduces its insulation properties and
becomes brittle with age.
⮚ Its use is limited to low voltage distribution and internal wiring as
paper-insulated cables have largely superseded them.
4. Impregnated paper:
⮚ it is quite cheap, has low capacitance, high dielectric strength
(30KV/mm), and high insulation resistivity (10Mohm-cm).
⮚ The main advantage is that a cable of given size can be worked out
at a higher current density than a VIR cable.
 Mechanical protection
❖ All the insulating materials used are mechanically weak,
so they require some form of protection for mechanical
injury.
❖ Mechanical protection is usually provided to power
cables laid direct in the ground by providing two layers
of steel tape.
 Color identification
 Color identification of bare conductors and cable
cores are given by EEU’S regulation
• Earthing -------------------------------------------------white
• Live of a.c single-phase circuit ----------------------Green
• Neutral of ac single or three phase ac circuit -------Black
• Phase R of three-phase ac circuit --------------------Green
• Phase S of three-phase ac circuit --------------------Yellow
• Phase T of three-phase ac circuit -------------------- Red
 Conduits
❖ Electrical conduits are used to protect and provide the route of
electrical wiring in an electrical system.
❖ Electrical conduits are made of metal, plastic, or fibre and can
be rigid or flexible.
❖ In general, conduits can be classified as:
i. Light gauge steel-plain (unscrewed) conduit.
ii. Heavy gauge steel-screwed (frequently used)
iii. Flexible conduit
iv. PVC conduit.
 Conduit Accessories and Fittings
❖ Wiring accessories are used for connecting appliances
❖ Conduit couplers:
❖ Bends elbows and tees:
❖ Conduit boxes
i. For providing connections to light, fan, and other points (outlet
boxes ) .
ii. For pulling of cables in to the conduits (inspection boxes) .
iii. For housing junction of cables (junction boxes) .
 Lighting Accessories and Fittings
❑ Switches: are used to control lighting circuits.
❖ Most are rated at 5/6A, but ratings at 15A are also available.
❖ Are available in three types: single pole, two-way and four-way
(intermediate).
❖ To control a number of different circuits from one position,
switches are contained within the same unit: two-gang, six-gang,
❖ Switches for water-heaters are of the double pole type and rated to
carry 20A.
2

Lighting Accessories and Fittings

2

Lighting Accessories and Fittings

 Lighting Accessories and Fittings
❑ Lamp Holders:
❖ Are designed for quick removal and replacement of the lamp and
yet they must hold the lamp in firm metallic contact to prevent
overheating.
 Lighting Accessories and Fittings
❑ Plugs and socket outlets:
❖ Socket outlets are used to enable portable apparatus to be connected
to the fixed wiring and comprises of two or three contact tubes and
terminals.
❖ The plug is the movable part connected to the apparatus by flexible
wire.
❖ They have different current ratings depending up the apparatus load
connected to it.
Lighting Accessories and Fittings
 Protection Accessories
❑ Fuses
❑ consists of a piece of thin copper (lead alloy) wire, which will melt
when carrying a predetermined current.
❑ The time for blowing out of a fuse depends on the magnitude of
excess current.
❑ Three terms are used in connection with fuses.
❖ Current rating: is the maximum current that a fuse will
carry without being blow.
❖ Fusing current: is the minimum current that will ‘blow’ the fuse.
❖ Fusing Factor: this is the ratio of minimum fusing current to the
current rating
 Protection Accessories
❑ Circuit Breakers
✔ It is a device designed to open and close a circuit by non- automatic
means & also to open the circuit automatically on a predetermined
over-current with out damage itself.
✔ They are rated in amperes (6, 10, 16, 20, 25, 35, 50, 63, 80, 100,
125, 160, 224, 250, 300, and large sizes).
✔ Most breakers will carry 150% of their rated load for perhaps a
minute, 200% for about 20 sec and 300% for about 5 sec.
 Protection Accessories
❑ Distribution Board
✔ A distribution board is a component of an electricity supply system
that divides an electrical power feed into subsidiary circuits, while
providing a protective fuse or circuit breaker for each circuit in a
common enclosure.
✔ The standard distribution boards usually have 4, 6, 8, 12, 18 or 24
fuse ways both single phase and three phases are available.
 Electrical accessories height
from finished floor
Typical mounting heights

Wall socket for utility room 450mm

Wall switch 1200mm

Wall socket for kitchen 1000mm

Telephone outlet 450mm

Wall lighting outlet 2100mm

Push button 1200mm

Elevator control button 1000mm

Bed lights 1800mm

bells, buzzers, chimes 2500mm when possible or 1500mm below ceiling

Fire alarms (gongs, bells, horns, lights) 2000mmabove floor finish line or 1500mmbelow ceiling
 Chapter Seven
Electrical Wiring Circuits
❑ The Electrical Wiring Systems are mostly standardized with
several rules, regulations and laws.
❑ Electrical Wiring must be installed correctly and safely in
accordance with electrical regulations and standards.
❑ If the electrical wiring is carried out incorrectly or without
confirming to any standard, then it may lead to incidents like short
circuits, electric shocks, damage the device / appliance or leads to
the malfunctioning of device which further causes for the
reduction of device life.
❑ Several factors have to be considered before the actual installation
work to be done for residential, commercial or industrial wiring.
❑ These factors include type of building construction, type of
ceiling, wall and floor construction, wiring methods, installation
requirements, etc
Electrical Wiring Circuits

❑ Distribution of Electrical Energy

✔ provides the electric supply up to the outside the consumer’s
premises (either residential, commercial or industrial).
✔ The consumer has to take the connection from that point to the
main distribution board / switchboard at home.
 Wiring diagram

Wiring diagram: Diagram showing practical implementation of

the Schematic diagram with connections actually made to the
electrical points.
✔ It gives detailed information about wiring such that one can get an
easy idea of making connection between the devices. It includes
relative position, arrangement of the devices and also terminals on
the devices.
✔ It shows power supplies and earth connections, control and signal
functions (with simplified shapes), termination of unused contacts
and leads, interconnection via plugs, blocks, sockets, terminal
posts, lead-through, etc.
 Electrical Diagrams

✔ Draw wiring and single line diagram of two lighting points, one fan to be
controlled by their respective switches, using looping in method. The switches are
in one casing (gang)
 Types of Electrical Wiring

⮚ We know that electrical circuit is a closed path through which

electricity flows from phase or hot wire to the device or apparatus
and then back the source though neutral wire.
⮚ Majorly, the wiring is divided into two types depending on the way
the devices are powered or connected to the supply. They are:
❑ Parallel Wiring
❑ Series Wiring
⮚ In Parallel Wiring, several devices on the installation are powered on a
single circuit. It is the most accepted wiring in homes and industries, in
which devices are connected in parallel with the supply source as shown
in figure.
⮚ In this, both phase (or hot) and neutral cables are routed through the
electrical boxes (junction boxes) from which individual receptacles,
fixtures, and devices are branched.
Parallel Wiring
 Series Wiring
⮚ The Series Wiring is the rarely used wiring in which hot wire is
routed through the several devices and then last device terminal is
connected to the neutral wire.
⮚ It is like an old Christmas lights or serial lights wiring in which one
light burnout leads to the shutdown of the entire network.
 Electrical Diagrams
• Lighting fixture controlled at one
position
 Electrical Diagrams
• Two lamp controlled at one position
using single double pole switch
 Electrical Diagrams
• One lamp controlled by two deferent
positions
 Electrical Diagrams
• One lamp controlled at three
different positions
 Chapter Eight
Industrial Installation
 A contactor is an electrically controlled switch used
for switching a power circuit, similar to a relay except
with higher current ratings.
 Contactors are used to control electric motors,
lighting, heating, capacitor banks, and other
electrical loads.
 The three main components of a typical contactor
are:
• Coil
• Contacts
• Movable Armature
 Chapter Eight
Industrial Installation
 Coil: The coil is an electromagnet that generates
a magnetic field when an electric current flows
through it.
 Contacts: The contacts are the conducting parts
of the contactor that make or break the electrical
circuit.
 Movable Armature: The movable armature, also
known as the plunger or core, is a mechanical
component that is attracted or repelled by the
magnetic field generated by the coil.
 Chapter Eight
Industrial Installation
Operating principle of contactor
 Coil energization: When an electric current is
applied to the coil of the contactor, it becomes
energized.
 Magnetic field generation: The energized coil
creates a magnetic field around it.
 Attraction of the armature: The magnetic field
generated by the coil attracts the movable
armature, also known as the plunger or core.
 Contact closure: As the armature is attracted by
the magnetic field, it moves towards the coil,
closing the contacts.
 cont.
 Electrical power flow: With the contacts closed,
electrical power can flow through the contactor. For
example, in a motor control application, the
contactor allows the motor to be energized and
start running.
 Coil de-energization: When the electrical current to
the coil is interrupted or turned off, the coil
becomes de-energized. As a result, the magnetic
field generated by the coil collapses.
 Armature release: With the magnetic field gone, the
armature is no longer attracted and is released.
This allows springs or other mechanisms to return
the armature to its original position.
 Contact opening: As the armature moves back, it
opens the contacts, interrupting the flow of
electrical current.
cont.

contact
co
F Double circuit Push
Forward’s main
button OLR – Over Load Relay
contact
M magnetic Coil
C

R Reverse’s main
Single circuit Push
contact
button R
Reverse’s magnetic Δ Delta Coil
Coil

O.L.R. normally close

Stop Push button
Forward’s magnetic Coil
F Y Star Coil
O.L.R. normally open

S Stop indicator lamp

F normally open T
Timer’s Coil

R normally open Forward indicator lamp

F 3-phase motor
3-Ø
Time Delay
Closing (TDC)
F normally close
Reverse indicator lamp
R

R normally
close Time Delay
O Over load indicator lamp Opening (TDO)
1-phase motor
1-Ø
 cont.
Motor Controllers Symbols
(European Format)
K1 Overload Relay
Normally Close
F2 Double Contact K1 Main
Main
Pushbutton magnetic Coil
Contact

S2
Overload Relay
K2 Delta Coil
Normally Open
F2
F2 Auxiliary
Overload K1 Normally Close
Relay
K3 Star Coil

Single Contact
Pushbutton N.C. Auxiliary
S0 K1 Normally Open
F3

Circuit
Single Contact
Breaker
Pushbutton N.O.
S1
 cont.
Methods of motor starting
In general, there are five basic methods of starting
induction motors.
1. Direct –on-Line(DOL) starting.
2. Forward and reverse starting.
3. Sequential starting.
4. Star-Delta or YWE-delta starting.
5. Autotransformer starting.
 cont.
1. Direct –on-Line (DOL) starting, Controlling circuit.
I. Control Circuit
III. Power Circuit
L1
N
STOP START

M L1 L2 L3
C

O.L. R.

N.O.
3-phase Circuit breaker

II. Indicating Circuit

L1 N M M M

N.C.
OLR OLR OLR
S

N.O.
T1 T2 T3
R
3-
Phase
O.L.R
Motor
.
O
 cont.
2. Forward and reverse starting circuit diagram

L1 L2 L3
I. Control Circuit III. Power Circuit

L
N
STOP Forward Reverse
F R 3-phase Circuit
breaker

O.L. R.
F R R F

F F F R R R
L1 N

F R
S

OLR OLR OLR

R
R
II. Indicating Circuit
T1 T2 T3
F
F
3-
Phase
O.L.R Motor
.
O
 cont.
3. Sequential motor starting system
 cont.
4. Star Delta or Wye Delta Electric Motor Controller
 cont.
4. Star Delta or Wye Delta Electric Motor Controller