3037 - Electrical Workshope Practice

ELECTRICAL WORKSHOP PRACTICE
(3037)
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DEPARTMENT OF ELECTRICAL & ELECTRONICS

ENGINEERING
ELECTRICAL WORKSHOP PRACTICE DEPARTMENT OF EEE
LIST OF EXPERIMENTS
TOPICS PAGE NO.

ELECRICAL SYMBOLS 04-06
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WIRING MTERIALS 07
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TOOLS 09
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ONE LAMP CONTROLLED BY ONE SWITCH 10
TWO LAMP CONTROLLED BY TWO SWITCH WITH
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SOCKET OUTLET
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STAIR CASE WIRING 14
HOSPITAL WIRING 16
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GODOWN WIRING 18
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MASTER SWITCH CONTROL WIRING 20
INTER MEDIATE SWITCH WIRING 22

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HOUSE WIRING 24
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TESTING OF INSULATION RESISTANCE 26

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CEILING FAN 29
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ELECTRIC IRON BOX 36

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ELECTRIC MIXER 42
MA’DIN Polytechnic college 2

SAFETY RULES
(Electricity is a good servant but a bad master)
1. SAFETY is of paramount importance in the Electrical Engineering Laboratories.

2. Electricity NEVER EXECUSES careless persons. So exercise enough care and attention in
handling electrical equipment and follow safety practices in the laboratory.
3. Avoid direct contact with any voltage source and power line voltages. (Otherwise, any
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such contact may subject you to electrical shock)
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4. Wear rubber-soled shoes. (To insulate you from earth so that even if you accidentally
contact a live point, current will not flow through your body to earth and hence you will
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be protected from electrical shock)
5. Wear laboratory-coat and avoid loose clothing. (Loose clothing may get caught on an
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equipment/instrument and this may lead to an accident particularly if the equipment
happens to be a rotating machine)
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6. Girl students should have their hair tucked under their coat or have it in a knot.
7. Do not wear any metallic rings, bangles, bracelets, wristwatches and neck chains. (When
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you move your hand/body, such conducting items may create a short circuit or may touch
a live point and thereby subject you to electrical shock)
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8. Be certain that your hands are dry and that you are not standing on wet floor. (Wet parts
of the body reduce the contact resistance thereby increasing the severity of the shock)
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9. Ensure that the power is OFF before you start connecting up the circuit.(Otherwise you
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will be touching the live parts in the circuit)

10. Get your circuit diagram approved by the staff member and connect up the circuit strictly
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as per the approved circuit diagram.

11. Check power chords for any sign of damage and be certain that the chords use safety
plugs and do not defeat the safety feature of these plugs by using ungrounded plugs.
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12. When using connection leads, check for any insulation damage in the leads and avoid
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such defective leads.

13. Do not defeat any safety devices such as fuse or circuit breaker by shorting across it.
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Safety devices protect YOU and your equipment.

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14. Switch on the power to your circuit and equipment only after getting them checked up
and approved by the staff member.
15. Do not make any change in the connection without the approval of the staff member.
16. In case you notice any abnormal condition in your circuit ( like insulation heating up,
resistor heating up etc ), switch off the power to your circuit immediately and inform the
staff member.

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TOOLS
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Exp No:
Date
ONE LAMP CONTROLLED BY ONE SWITCH

AIM:-
To wire up a circuit in conduit system one lamp controlled by one switch
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TOOLS AND INSTRUMENTS REQUIRED
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1. Steel rule 300mm 1No
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2. Combination Plier 200mm 1No
3. Electricians Knife 1No
4. Screw driver 200mm, 10mm 1No
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tip
5. Ball peen hammer 220gm 1No
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6. Gimlet 25mm 1No
7. Neon tester 0-500V 1No
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8. Wire stripper 1No
9. Firmer chisel 5/8” 1No
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ESTIMATE:-
SI NAME OF METERIALS SPECIFICATION QUANTITY UNITS REMARKS
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PROCEDURE:-
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1. Draw the lay out and connection diagram.

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2. Collect the required wiring materials.
3. Connect the required materials on the work board as per connection diagram.
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4. Check the circuit for continuity.

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5. Given the supply to the circuit after checking.

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6. Finished the work neatly and correctly.

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RESULT:-
wired up a circuit in conduit system one lamp controlled by one switch

Exp No:
Date
TWO LAMP CONTROLLED BY TWO SWICTH WITH SOCKET OUTLET
AIM:-
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To wire up a circuit in conduit system two lamps and a socket out let each controlled
independently.
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tip
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6. Gimlet 25mm 1No
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LAY OUT CONNECTION DIAGRAM

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ESTIMATE:-
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PROCEDURE:-
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RESULT:-
wired up a circuit in conduit system two lamps and a socket out let each controlled
independently

Exp No:
Date
STAIR CASE WIRING

AIM:-
To wire up a circuit in conduit system one lamp controlled by two switches (stair
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case wiring) in deferent places.
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tip
6. Gimlet 25mm 1No

ESTIMATE:-
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PROCEDURE:-
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RESULT:-
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wired up a circuit in conduit system one lamp controlled by two switches (stair case wiring) in
deferent places

Exp No:
Date
HOSPITAL WIRING
AIM:-
To wire up a circuit in conduit system two lamps controlled by two switches (one
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way and two way hospital wiring
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tip
6. Gimlet 25mm 1No
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ESTIMATE:-
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PROCEDURE:-
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RESULT:-
wired up a circuit in conduit system two lamps controlled by two switches (one way and two
way hospital wiring

Exp No:
Date
GODOWN WIRING
AIM:-
To wire up a circuit in conduit system as per layout and conditions (go down wiring)
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tip
6. Gimlet 25mm 1No
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ESTIMATE:-
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PROCEDURE:-
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RESULT:-
wired up a circuit in conduit system as per layout and conditions (go down wiring)

Exp No:
Date
MASTER SWITCH CONTROL WIRING

AIM:-
To wire up a circuit in conduit system by putting Lamps from different places
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independently and from one specific place by a Master Switch.
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LAY OUT
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CONNECTION DIAGRAM
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tip
6. Gimlet 25mm 1No
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ESTIMATE:-
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PROCEDURE:-
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RESULT:-
wired up a circuit in conduit system by putting Lamps from different places independently and
from one specific place by a Master Switch.

Exp No:
Date
INTERMEDIATE SWITCH WIRING

AIM:-
To wire up a circuit in conduit system by putting One lamp from multiple places using
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intermediate switch (more than two places).
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LAY OUT
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CONNECTION DIAGRAM
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tip
6. Gimlet 25mm 1No
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ESTIMATE:-
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PROCEDURE:-
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RESULT:-
wired up a circuit in conduit system by putting One lamp from multiple places using
intermediate switch (more than two places).
Exp No:
Date
HOUSE WIRING
AIM:-
To wire up a circuit in open conduit system (house wiring).
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CONNECTION DIAGRAM
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tip
6. Gimlet 25mm 1No
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ESTIMATE:-
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PROCEDURE:-
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RESULT:-
wired up a circuit in open conduit system (house wiring).

Exp No:
Date
TESTING OF INSULATION RESISTANCE

AIM:-
To conduct the following tests for new electrical installation
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1. Insulation resistance between conductors
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2. Insulation resistance between conductor and earth
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PRINCIPLE:-
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Before new electrical installation or an addition to an existing installation

is to be connected to supply mains the above tests have to be carried out to
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ensure that there is no defect in the installation which may cause danger and is
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in accordance with Electricity Rules. Insulation resistance between conductors

is conducted to ensure that the insulation of the cables or wires is not damaged
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and there is no leakage between them. Insulation resistance between

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conductor and earth is conducted to ensure that the cables used in wiring are
sufficiently insulated to avoid leakage of current to earth.
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PROCEDURE:-
Insulation Resistance between Conductors
1. Switch off the main switch and remove fuse carriers.

2. Remove all the lamps from their holders.
3. Disconnect all the appliances.
4. Keep switches in ON position.
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5. Keep all distribution fuses / MCBs in ON position.
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6. Connect the one lead of the megger in to phase and other lead to neutral wire.
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7. Rotate the megger and measure the insulation resistance.
8. Finish the work and submit for inspection.
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Insulation Resistance between Conductor and Earth
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1. Put the main switch ON position
2. All the fuses in main switch should be in position
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3. All the fuses / MCBs in DB in ON position.
4. The lamps, fans and other loads should be in their position.
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5. All switches should be in ON position.
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6. Short the phase and neutral of the socket with wire.

7. Short the line and neutral cables at the main switch.
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8. Connect the shorted lead to the ‘L’ terminal of the megger.

9. Connect the earth to the ‘E’ terminal of the megger.
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10. Rotate the megger at its rated speed.

11. Measure the insulation resistance and it should not be less than 1M.
Finish the work and submit for inspection.
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RESULT:-
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1. Measured the insulation resistance between conductors = Ω

2. Measured the insulation resistance between conductor and earth = Ω

Exp No:
Date
CEILING FAN
AIM:-
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To study the construction and working of ceiling fan and ending the trouble shoot
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problems
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APPARATUS REQUIRED:-
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Test lamp, bearing puller, Ceiling fan
TOOLS REQUIRED:-
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Combination pliers, Tester, Screw driver, Multi meter
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OBJECTIVE:-
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 Explain the construction of ceiling fan

 Describe the causes for common faults and their remedy
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 Describe the dismantling and assembling procedure for a ceiling fan

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AIM:-
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The fans consists of the following parts

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1. Rotating part
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2. Stationary part
The rotating part consists of
 Rotor (Body)
 Fan blades
 Bearings
 Squirrel cage winding (rotor)

The stationary parts consists of

 Canopy
 Shackle bolt, nut and split pin
 Suspension rod (Down rod)
 Terminal block
 Capacitor
 Stator winding
 Running winding
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The information about the rating is available from the name plate which is fixed on
the body of the fan.
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In generally most ceiling fan and table fan have a capacitor start permanent
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capacitor motors which a difference from usual motor that it central position (Rotor/
Armature) remains fixed, while the outer portion rotates blades are mounted on the
outer shaft when the motor is energized the blade cause to rotate and to circulate the
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surroundings are depends on the speed of fan. A regulator is connected in series with
fan at different tapings hence the speed of the fan consist of a number of parts are
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connected together as a shaft to avoid loose fittings the parts are located bolts, split,
pins and bearing lock.
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Usually a ceiling fan and table fan consist of a capacitor start and run motor.
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Capacitor are connected in the circuit at all times the advantages of leaving the
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capacitor permanently in circuit are,

 Improve the over load capacity of motor
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 Higher power factor

 Higher efficiency
 Quit running of the motor
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It has one starting winding in series with one capacitor and running winding since
the capacitor remains in the circuit permanently. This motor is often referred to as
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permanent. Split capacitor runs motor and behaves practically like an unbalanced 2
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phase motor.

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CONNECTION DIAGRAM
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COIL CONNECTION FOR CEILING FAN
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POSSIBLE FAULT AND REMODIES:-
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Fan not working
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CAUSES TEST REMEDIES

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1.Dry bearing. If the bearing Check grease and quality of By giving oil or grease this
with dry bearing ( without oil grease after removing defect can be rectified
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or grease) or brush friction

increase heat produced and
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either rotate at low speed

2.No supply on wall socket Test continuity If it is wiring fault, rewire it
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3.Regulator has open circuit Test the regulator If it is regulator fault replace
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it
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4.Faulty capacitor Check the capacitor by Replace if necessary

supply or multi meter
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5.Faulty regulator Check the regulator by series Replace if necessary

test lamp
6.Open or Short circuit on Check the field winding Rewind if necessary

field winding

Fan works at low speed
CAUSE TEST REMEDY

1.Low voltage Check the supply voltage Give correct supply
2.Faulty capacitor Check capacitor Replace by new one
3..Winding fault Check the winding Rewind if necessary
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4.Weak field winding Check the insulation Repair it
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resistance of field winding
Fan working at low speed and become hot
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CAUSE TEST REMEDY
1.Capacitor is burn out Capacitor test Replace it
2.Blade are bended To set the blade in correct If bend is occur straighten by
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position take them out from pushing or using a mallet
the grill, place the blade on
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the flat and clean floor in
such a position so the blades
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may touch the floor
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3.Winding shorted Test using series test lamp Replace winding

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4.Winding earthed Test for continuity There must be earthed by an

earth wire coming from the
wall socket by the third wire
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in the load
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Fan gives shock

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CAUSE TEST REMEDY

1.Winding may be earthed Test for continuity There must be earthed by an
end cover may be touching earth wire coming from the
the open portion of winding wall socket by the third wire
in the load
Other faults
FAULT CAUSE & TEST REMEDY

1.Fan is working at high Test for continuity Repair or replace the
speed only regulator
2.Fan is not working at high Capacitor defective Replace

speed if position 5 Winding defective Rewind
Regulator defective Replace
3.Fan produces sound when Capacitor defective Replace
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switch is ON Winding defective Rewind
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4.Fan is working with high Bearing tight Replace old bearing
sound Give grease or oil
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ASSEMBLING:-
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Assembling the dismantled parts in the reverse order to that of dismantling. Check
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the screws whether they are tightly fitted before installing the ceiling fan care has to
be taken to test the fan for its insulation between the winding and the body.
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RESULT:-
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Studied about ceiling fan and table fan and prepared the maintenance chart.
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Exp No:
Date
ELECTRIC IRON BOX
AIM:-
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To find the fault of iron box (ordinary and automatic) and study about them and
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prepare the maintenance chart of the possible faults and their remedies
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MATERIALS REQUIRED:-
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Iron box, Test lamp, Wires
TOOLS REQUIRED:-
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Tester, Pliers, Stripper etc.,
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THEORY:-
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ELECTRIC IRON BOX

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An electric iron box is used to iron the cloths. Electric iron box can be classified into two
types as below
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 Ordinary Electric Iron Box

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 Automatic Electric Iron Box

ORDINARY ELECTRIC IRON BOX
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It consists of Chromium plated base plate, Heating element,

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Pressure plate and Iron case with Handle
Sole Plate
It is made up of Cast iron and its bolts is Nickel plated with very shining like glasses.

Heating Element
It is made up of flat Nichrom wire and wound on a Mica sheet. Its wattage
varies 450, 500, 1000 etc.,
Pressure Plate
It is made up of Cast iron. Its shape as heating element. It sets and presses the
heating element on sole plate with the help of two machine screws and nuts.
Iron Case
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It is used for covering the all above parts. In which an insulator terminal and
handle is provided. It is make up of iron sheet with Nickel plating.
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Wooden or Ebonite Handle
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It is used for holding the bar terminal with stand washers.
Porcelain Sheet
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Nut, Bolt and Washers are used to tighten the weight plate and iron case
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should be insulated by insulating materials like Porcelain sheet, Mica sheet,
Ebonite sheet
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AUTOMATIC ELECTRIC IRON BOX

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In addition to the above mentioned iron box, the automatic iron box has a
thermostat which is connected in series with the element. This thermostat
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controls the temperature. Prevent over heating of iron and thus avoids damage
to the heating element. The required temperature can be obtained with the
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help of thermostat.
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Principle of Operation
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An electric iron box works on the principle that when an AC current passed
through a resistive wire the electrical energy is transferred to heat energy. The
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Nichrome wire is heated up to a certain temperature and gets a bright orange-

red colour. The wire used in heating element generally made by Nichrome
wire which is a combination of 15% Chromium 20% Iron and remains Nickel.

Testing
1. By connecting the two ends of connecting lamp leads to the terminals of

iron box
 If lamp glows dimly it means that element is in working order
 If the lamp does not glow it means that the breaking
in the heating element
 If the lamp glows brightly the both sides of the
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element touching the sole plate
2. The earth testing by connecting one lead to one terminal of electric iron
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and other lead to metal parts of the element if the lamp give full light or
dim light, there is a leakage in the iron. If the lamp does not glow , the iron
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is good
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AUTOMATIC IRON BOX
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CIRCUIT DIAGRAM OF IRON BOX
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POSSIBLE FAULTS AND REMEDIES:-
DEFECT CAUSES REMEDIS

1.The iron box does not get Power failure Check the supply
started Loose connection Check the
connection
Replace the heating element
Break on heating element
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2.Touching give shock Live part is touching on body Insulate live part
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3.Slow heating Lack of rated voltage Improve the voltage
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4.In an automatic iron box The thermostat is not Replace the thermostat
power does not break working by new one
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which maintaining the
required temperature
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RESULT:-
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Studied the methods to find out the fault of a ordinary and automatic iron box and
prepared the maintenance chart.
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Exp No:
Date
ELECTRIC MIXER
AIM:-
To study about electric mixer and find out fault in it
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APPARATUS REQUIRED:-
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Electric mixer
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TOOLS REQUIRED:-
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Screw driver, Combination pliers, Test lamp, Tester, Knife
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PRINCIPLE:-
It is worked on by using a universal motor. A universal motor may be operated either on DC or

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Single phase AC supply. Approximately same output.

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Being a series wound motor it has high starting torque and a variable speed characteristics. It
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runs dangerously high speed on no load. That’s why such motors are would built into a device
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driver.
I which tapings field method is usually employed for speed control purpose. In this method a
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field plate is tapped various points and speed is controlled by field strength for this purpose
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either of the following two arrangement may be used.

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 The field pole is wound in various sections with different sizes of taps are brought out
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from each sections.

 Nichrome resistance is wound over one field pole and taps are brought out from te
wire.

RELATED INFORMATIONS:-
Electric mixer is born for house purpose. It’s very useful appliance for grinding. Another use of
mixer is prepare fruit juice.
The speed of mixer is high. The mixers are available in small medium and large sizes. Large size
one is the mostly used for commercial purpose. The electric mixer can be divided into three
parts from construction point of view.
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Base
The base portion houses an electrical universal motor with a ON , OFF switch or a selected
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switch. If it is a multi speed motor.
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Grinder and Blender
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Grinder is of two types. The one is for fruit juice, vegetable juice, etc... It’s called blender for
grinding dry and hard pieces. The blades of grinder are small in size and are made of hard
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stainless steel.
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Bowl
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The material to be grinded or mixed is put into the bowl after the preparation of it. Ready the
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bowl along with the grinder is detached from the shaft of the motor. The content are then
poured out.
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The bowl grinding blades are coupled to the motor with the help of Dayton coupling.
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POSSIBLE FAULT AND REMODIES:-

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1. Mixer grinder is heating

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CAUSE TEST REMEDY

1.Overload Check the load. Reduce it.
2. Low or high supply Check the supply voltage. Give proper supply.
voltage. .
If it’s not normal tight it to
Check the tightness of bearing
3. Bearing and couple are too appropriate level.
and couple.
tightened.

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CONNECTION DIAGRAM
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2.Mixer does not exist.

1. Supply does not exist. Check for continuity. Replace if necessary.
2. Couple is mechanically Check rotation. Dismantle if required and test.

block.
Replace if it necessary.
3. Coil are open circuited. Test the field coil for open
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circuit (test lamp).
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4. Complaint on over load Check for switch with test
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switch. lamp.
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5. Defective the selection Check rotatory switch.
switch.
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6. No adequative pressure on
brush holder.
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Replace the coil if required.
7. Short circuit on armature. Check the armature by
growler to located
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effective coil.
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3. Mixer makes sound

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CAUSE TEST REMEDY

1. Bearing problem. Check the bearing. Replace it or replace if is
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necessary.
2. Improve coupling. Check the joining of couples Make it correct.

and jar. Give proper supply.
.

4.Low speed
1. Short circuit on winding. Check for winding. Rewind if necessary.
2. Speed can’t be varied. Check rotary switch. Repair or replace it.
3. Get shocks from body. Check water leakage inside Clean and warm it in sun light.
of it.
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4. Decrease of sharpness of Check t Replace blade and brush.
blade or brush complaint.
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5. Get shock from code wire Check insulation of code Replace if it.
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wire.
6. Short circuit in armature or Check commutator Replace it.

commutater. insulation.
7. Too tight to the working

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Check bearing and brushes. Replace it if it is faulty.
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motor.
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RESULT:-
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Studied about an electric mixer and find out parts in it and dismantle and assemble
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the parts.

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ELECTRICAL WORKSHOP PRACTICE

DEPARTMENT OF ELECTRICAL & ELECTRONICS

TOPICS PAGE NO.

TWO LAMP CONTROLLED BY TWO SWITCH WITH

MASTER SWITCH CONTROL WIRING 20

INTER MEDIATE SWITCH WIRING 22

TESTING OF INSULATION RESISTANCE 26

ELECTRIC IRON BOX 36

MA’DIN Polytechnic college 2

1. SAFETY is of paramount importance in the Electrical Engineering Laboratories.

will be touching the live parts in the circuit)

as per the approved circuit diagram.

such defective leads.

Safety devices protect YOU and your equipment.

MA’DIN Polytechnic college 3

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MA’DIN Polytechnic college 9

ONE LAMP CONTROLLED BY ONE SWITCH

To wire up a circuit in conduit system one lamp controlled by one switch

MA’DIN Polytechnic college 10

1. Draw the lay out and connection diagram.

2. Collect the required wiring materials.

4. Check the circuit for continuity.

5. Given the supply to the circuit after checking.

6. Finished the work neatly and correctly.

wired up a circuit in conduit system one lamp controlled by one switch

MA’DIN Polytechnic college 11

TWO LAMP CONTROLLED BY TWO SWICTH WITH SOCKET OUTLET

7. Neon tester 0-500V 1No

9. Firmer chisel 5/8” 1No

LAY OUT CONNECTION DIAGRAM

MA’DIN Polytechnic college 12

1. Draw the lay out and connection diagram.

2. Collect the required wiring materials.

4. Check the circuit for continuity.

5. Given the supply to the circuit after checking.

6. Finished the work neatly and correctly.

MA’DIN Polytechnic college 13

STAIR CASE WIRING

TOOLS AND INSTRUMENTS REQUIRED

1. Steel rule 300mm 1No

6. Gimlet 25mm 1No

1. Draw the lay out and connection diagram.

2. Collect the required wiring materials.

4. Check the circuit for continuity.

5. Given the supply to the circuit after checking.

6. Finished the work neatly and correctly.

MA’DIN Polytechnic college 15

TOOLS AND INSTRUMENTS REQUIRED

1. Steel rule 300mm 1No

1. Draw the lay out and connection diagram.

2. Collect the required wiring materials.

4. Check the circuit for continuity.

5. Given the supply to the circuit after checking.

6. Finished the work neatly and correctly.

MA’DIN Polytechnic college 17

MA’DIN Polytechnic college 18

TOOLS AND INSTRUMENTS REQUIRED