Introduction

General Electrical safety

1. Conduct in a responsible manner in the laboratory.

2. Be sure that all equipment is working before using them.
3. Follow all written and verbal instructions carefully.
4. Do not use damaged or uninsulated materials.
5. Never work alone in the workshop.
6. Always check all circuits connection’s before applying power.
7. Wear the proper cloths and safety gloves in working areas.
8. Always switch the off power before changing connections.
9. Keep your work area clean and organized.
10. Don’t give power or energize equipment until you get permission.
11. After you done the work turn main switches off
12. No smoking, no food and no drinks permitted inside laboratory.

Common types of Electrical Hand Tools

Objective:
1. Identify different hand tools used in workshops.

2. Familiarize with the different types and functions of hand tools.

3. Familiarize with the workshop tools and safety rules.

Basic tools are:
1. Screwdrivers: is used to insert and tighten or to loosen and remove screws. Types (Philips
and flat)

2. Wire strippers: are small hand-held devices used to strip the insulation from electric
wires.
3. Side cutters: are used for cutting extra components leads.

4. Wire crimpers: are used to connect two wires or two conductors together.

5. Electrician knife-stainless-steel, with wooden or plastic handle.

6. Multimeter, handheld, digital

7. Clamp & insulation meter

8. Pliers-The smoothly ground and polished box joint head hives zero play with high lateral
stability.

9. Pliers: Round nose, flat nose and side cutting pliers

10. Screw driver-Flat A Screw driver which provides a powerful torque to screw in to most types
of material. Featuring forward or reverse drive.

11. Round (Philips) Screw driver-which provides a powerful torque to screw in to most types of
material. Featuring forward or reverse drive

12. Side cutter-A diagonal side cutter with spring loaded handles, handles, polished jaws and
flush cutting facilities

13. Hammer (ball pin or claw)-Stainless steel, medium size pvc /wooden handle

14. DRILL machine

15. Soldering iron, lamp holder, cable/ wire, PVC, MCB box, etc.

Different methods of splicing, joining, termination and soldering.

Splicing:- Conductor joints (splices) – the connection of two lengths of conductor by a method
which insures a continuous path for unimpeded flow of an electric current.
To branch electrical power from transmission lines to your home, you need to make splices
between the transmission lines and the branching lines to your home.
Materials required
 Copper wire
 Pliers: 2
 Pocket knife: 1
 Soldering iron: 1
 Solder, insulating tape

Procedure
1. simple twist joint

1. Remove the insulation of the wires for a distance of about 7 cm.

2. Place them in a crossed position about 2 cm from the insulation and bent in such a way as to
make a long twist and bring it back into the form of a cross.
 3. Wrap four or five short turns on each of the long twist.

4. Cut off the free ends and squeeze down close to the straight position of that wire so that they
will not extend over the surface of the short turns and permit the sharp ends to cut through the
tape with which the joint is to be wrapped.

Simple twist joint

5. Solder the joint.
6. Cover the joint with rubber tape; wrapping at one end at least 5 mm back on the original
insulation of the conductor and extend over to the other side for a similar distance on the
insulated covering.

2. Married Joint

When wires having a number of strands are joined together, the joint made is called ‘married
joint’.
1. Remove the insulation about 8 cm from one end of each piece.
2. Remove the braiding about 1.5 cm on each wire and clean with sand paper.
3. Re-twist the wires about 2.4 cm length, but remaining portion of strand is kept open.
 4. The two pieces are closed together with conductors intersecting each other.

5. Twist the strand one by one over the other closely and tightly.
6. Repeat steps 5 on the other side with second piece.
7. Round of the ends with pliers.

8. Solder and cover with insulation tape as you did in part 1.

3. Single strand ‘T’ Joint

This type of joint is necessary where it is required to tap energy from running line.
1. Remove the insulation of the running wire for a length of about 5 cm and clean gently the
conductor.

2. Remove the insulation of the wire to be joined.

3. Place the branch wire at 900 to the running wire, make a hook turn of the branch conductor
and wrap it on the running wire.
 4. Solder and cover with tape.

4. Three strand ‘T’ Joint

This method of splicing is used for a three strand wire.

1. Remove the insulations of the running and branch wires.

2. Close together the running and branching wires as shown in the fig.

3. Wrap one strand of the branch wire to the running conductor on one side.

4. Wrap the 2nd strand to the opposite side.

5. After gripping the running conductor, the third strand is wrapped to the branch conductor.
6. Solder and cover the joint.

5. Britannia Straight Joint- is applicable for bare wire splicing.

1. Remove the insulation from the two ends of the wires.

2. Bent the tail point of the bare conductor at right angle.

3. Splice the two wires together with the help of separate binding wire.

4. Follow similar steps you did for Britannia straight joint to make Britannia ‘T’ joint shown
below. (Optional)

Termination: –is the process of connecting lugs or connectors to the wire as well as the
preparation of the wire ends so as to enable them to be connected to the terminals of electrical
equipment. The point where a line, channel or circuit ends.

Soldering: is a process of joining metals or making allows.

It is a process of making a bond between two pieces of wire by melting a third piece of wire,
solder.
Example
Tin and lead ….
-in an electrical circuit soldering is connection of two work pieces both electrical and
mechanically through the use of another material, the solder.
The key factors that affect quality of soldering joints.
 Cleanliness
 Temperature
 Flux
 Time
 Adequate solder coverage: Are the key factors affecting the quality of the joint. A little effort
spent now in soldering the perfect joint may save you - or somebody else - a considerable
amount of time in troubleshooting a defective joint in the future. The basic principles are as
follows.
Cleanliness
It is essential for efficient, effective soldering.
Solder will not adhere to dirty, or oxidized surfaces. Heated metals tend to oxidize rapidly.
The reason in which oxides and dirty must removed by chemical or electromechanical means.
Flux
Flux
A second very important item in preparing to solder is the flux. Flux has a very definite purpose:
It prevents oxidation and removes the thin layer of oxide and the atmosphere gas layer from the
area to be soldered. When the flux is applied to the area, it permits the solder to flow, or wet,
smoothly and evenly over the surface of the lead, wire, or pad being soldered. It also improves
the flow of heat, resulting in faster heating of the items are area being soldered.