9 Electrical Equip. Mait - NSQF

GOVERNMENT OF KERALA
DEPARTMENT OF TECHNICAL EDUCATION
NATIONAL VOCATIONAL EDUCATION QUALIFICATIONS

FRAME WORK
LEARNING RESOURCE FOR

LEVEL 1
ELECTRICAL EQUIPMENT MAINTENANCE
CLASS IX
TECHNICAL HIGH SCHOOL
(As per Revised Curriculum - 2013)
STATE INSTITUTE OF TECHNICAL TEACHERS

TRAINING & RESEARCH
HMT Jn., KALAMASSERY - 683104
Phone & Fax: 0484 2542355

Email: jd_cdc@yahoo.com jd.cdc@dte.kerala.gov.in
Website: www.sitttrkerala.ac.in
PREFACE
Government of Kerala introduced Technical High School system in 1961
with the aim of inculcating technical learning at the High School level so as to
produce technically talented youth. This would help students establish a strong
foundation in engineering studies so that they could pursue higher studies in
Engineering. Products of THS system can obtain employment at Craftsman level
too. In the emerging global economy there are ample employment opportunities
for technically qualified persons.
The revised THS curriculum which has been introduced in 2013 provides
maximum scope for the students to develop themselves into globally competitive
citizens who are abreast with the new advancements in the field of Science and
Technology. The medium change from Malayalam to English is an added
advantage to realize this objective.
The learning resource on Electrical Equipment Maintenance is a comprehensive

introduction to the concepts and practices in the maintenance of various electrical
equipments. Safety practices, testing, measurements, installations etc are also included
The material is prepared in a language and style easily digestible to the

students of Technical High Schools. Several staff members of Technical Education
Department have contributed to the preparation of this learning resource. I take
this opportunity to extend my sincere gratitude to all of them.
N SANTHAKUMAR
JOINT DIRECTOR
SITTTR
KALAMASSERY
LEARNING RESOURCE PREPARATION COMMITTEE
Dr. S. Radhakrishnan, Joint Director, RDTE, Kothamangalam (Chairman)
Smt. A.S.Chandrakanta, Principal, Govt.Women’s Polytechnic College, Thrissur
Shri. P. P. Baby, Asst.Director, Supervisory Development Centre, Kalamassery
Shri.T. V. Francis, Project Officer, SITTTR, Kalamassery
Shri. Biju Peter, Project Officer, SITTTR, Kalamassery
Technical Co-ordinator
V A Shamsudeen, Deputy Director, SITTTR, Kalamassery
Technical Expert Committee

Shri. P. Babu., HOS in EEE, SRGPTC, Triprayar.
Shri. Vijai.T.V, Lecturer in EEE, GPTC, Palakkad.
Shri. Manohari.C.B, Lecturer in ECE, WPTC, Thrissur.
Shri. Aneef.A, Demonstrator in EEE, GPTC, Palakkad.
Scrutiny Committee
Mrs. Anna Tergy, Principal, TPTC Alagappanagar
Mr. Augustine Kuriyakose, Lecturer in EE, GPTC Palai
Design & Layout : Smt. Shincy T P, Women’s Polytechnic College, Thrissur

Cover Design: Shri. Babu K R, SITTTR, Kalamassery
INSTRUCTIONS TO TEACHERS
The learning resource for imparting practical training in state trades and
NSQF specializations have been specially structured as follows:
The resource material is presented in two blocks-Blocks I and Block II. The
key part is the Block II, which provides the list of exercises to be carried out for the
student to practically learn the topic and acquire the appropriate skill. But this process
would require understanding the basic concepts and general ideas in the topic. This is
what is presented systematically in Block I. Thus Block I constitutes the theoretical
concepts required for the exercises in Block II. The methodology to be adopted by the
teacher in handling this practical course is listed below.
i Provide a general introduction to the subject from the appropriate beginning

portions of Block I.
ii Proceed to Block II. For each exercise in Block II, identify the concepts
required for clearly understanding the practical work, teach those from Block
I and complete the practical work as detailed in Block II.
iii In the above manner, both the blocks have to be completely covered
concurrently thereby ensuring that the students gain competence in both
practical as well as theoretical aspects, in a systematic manner.
Suggestions for improvement of the structure and presentation of the learning

resource may be communicated to the undersigned or to the Curriculum Development
Cell, Kalamassery.
Dr. S. Radhakrishnan,
Chairman, Learning Resource Committee for THS

CONTENTS
BLOCK 1 THEORY
CHAPTER 1. SAFETY PRACTICES
Page No.
1.1 Safety .. 12
1.2 Classifications of safety .. 12
1.3 Safety at work .. 13
1.4 Fire safety .. 17
1.5 Electrical Safety .. 22
CHAPTER 2. BASICS OF ELECTRICITY 33

2.1 Introduction to Electricity .. 34
2.2 Resistance .. 35
2.3 Ohm’s Law .. 36
2.4 Basic Electric Circuit .. 37
2.5 Types of Electric Current .. 40
2.6 Electric Power .. 42
2.7 Electrical Energy .. 43
2.8 Testing of Electric Supply and Polarity .. 48
2.9 Identifying phase, neutral and earth wires .. 49
CHAPTER 3. JOINTS AND WIRING

3.1 Skinning .. 54
3.2 Soldering .. 54
3.3 Crimping and crimping tool .. 55
3.4 Joints in Electrical conductors .. 55
CHAPTER 4
EARTHING AND ENERGY METER INSTALLATION
4.1 Earthing .. 72
4.2 Types of Earthing .. 75
4.3 Earthing Domestic installation .. 77
4.4 I S specification regarding earthing of electrical installations . . 78
BLOCK 2 PRACTICAL
CHAPTER 1 SAFETY PRACTICES .. 81
1. To lift a heavy motor to a table using any approcpriate method.

2. To make a fire and extiguish the fire using a suitable fire
extinguisher.
3. Identify the safety measures you can implement in your
institution.
4. Practice Mock treatment for a person affected electric shock .
5. Collect different tools used for electrical maintenance and wiring
and write the specifications.
CHAPTER 2 BASICS OF ELECTRICITY .. 85
1. Measurement of resistance .. 85
2. Connecting lamps in series .. 87
3 Connecting lamps in parallel .. 89
4 Testing the polarity of dc supply .. 91
5 Testing the polarity of ac supply .. 92
6. Verification of AC Power Supply (socket) Polarity .. 93
CHAPTER 3 JOINTS AND WIRING .. 95
1. Skinning .. 95
2. Crimping .. 96
3. Straight Joint .. 97
4. Married joint .. 98
5. Tee Joint .. 99
CHAPTER 4 EARTHING AND ENERGY METER

INSTALLATION .. 101
1. Prepare the list of material required for pipe earthing. .. 101
2. Energy meter installation .. 102
3. One lamp controlled by one switch .. 103
4. One lamp controlled by two switch .. 104
5. Two lamps controlled by two switches independently .. 105
6. Two lamps controlled by one switch .. 106
7. Two lamps controlled by one switch in series .. 107
8. Schematic layout in domestic wiring system .. 108
*******
11
Chapter-1
BLOCK I
SAFETY PRACTICES
Objectives
1. To introduce the concept of safety.

2. To know safety with respect to work, fire and electricity.
3. To understand the safe methods for handling heavy loads.
4. To know about fire and fire safety equipments.
5. To understand the causes and effects of electrical hazards.
6. To know about the protection and rescue measures from electrical hazards.
Note to the teacher
1. Display videos related to fire and safety.

2. Ensure familiarization of safety signs and symbols in color charts.
3. Display a chart listing the types of fires and extinguishers.
4. Conduct demonstration of H-N (Holger Nielsen) method of artificial respiration.
5. Conduct demonstration of fire-fighting with fire extinguisher.
6. Display a chart showing the severity of electric shock and its physiological effects.
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12 Electrical Equipment Maintenance
SAFETY PRACTICES
1.1 Safety
The condition of being protected from danger or accidents or a condition of not having hazards,
risk or injury can be termed as safety in a general sense.
Why safety?
Safety ensures health of individual, benefits to the occupation
and protects the environment. The concept of safety is standardized
as HSE which relates safety with health and environment. Safety
improves quality of worker, quality of product and reduces losses.
How can we ensure safety?

Safety can only be ensured by following the systematic procedure laid down for the particular
operation. Safety can be achieved through
• a safe working environment
• awareness of person involved about safety
• foresight of possible hazards.
1.2 Classification of safety
A. Safety at work
B. Fire safety
C. Electrical safety
Fig 1
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1.3 Safety at work

While doing a work whether at home or at work place, following the safe procedures can avoid
majority of accidents. A little care while doing a work can save a lot of effort, money, and often our
valuable lives.
Accidents do not just happen, they are caused!
Most of the accidents are caused by:

 ignoring the proper instructions to operate an
equipment.
 not using safety guards.
 using faulty or improper tools and equipments.
 negligent or overconfident actions.
 inadequate light & ventilation.

Fig 2
 doing more than one job at a time.
 unnecessary hurry.
 lack of knowledge.
Let us consider some of the safety precautions to be taken while at work:
1.3.1 Lifting & Handling of loads manually

Possible accidents and precautions:
Cuts and abrasions:
While working manually, there is chance of occurrence of cuts
and abrasions due to rough surfaces and edges or by sharp or pointed
edges.
PRECAUTIONS:
Wearing leather gloves will prevent accidents while handling

equipments. Take good care for any irregular surfaces,while
dealing with heavy loads. Fig 3
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Crushing of feet or hands:

Feet and hand can be trapped while lifting or moving a heavy load, causing severe pain and
damages to tissues and bones.
PRECAUTIONS: Feet and hands should be

positioned in a safe manner so as not to be trapped in
between the surfaces while lifting or lowering the heavy
loads. Wearing safety shoes can prevent crushing of
feet.
Fig 4
Straining of muscles and joints:
Sudden and awkward movements like twisting or jerking, while lifting a heavy load can
cause strain on muscles or injury to the back joints of a person. The human spine is not
suitable for lifting loads.
PRECAUTIONS :
• Make clear idea about what to lift, where to shift, how to do.
• Make sure that the route is clear for the movement.
• Ensure proper holdings for the load.
Safe lifting:
• Position in a comfortable way with legs

slightly apart.
• Then bend the knee such that the load is held

close to the body.
• Hold the load in a grip and keep the back

straighten in most vertical position.
• Gradually apply force to straighten the legs

so that the strain is completely taken by the
Fig 5
powerful thigh muscles.
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1.3.2 Moving Heavy loads

Heavy loads are lifted using heavy equipments like Cranes, Winches, Moving Platforms,
rollers, etc.,
Using Cranes & slings:
Slings are tied to the load so as to distribute the
weight of the load evenly. The slings used should not
have cuts or abrasions, wear or corrosion.
• Use the slings near to vertical position.
• While lifting, take care to avoid crushing of
objects of personnel in between the load
and other objects.
• Obstacles in the lifting way should be
removed.
• Warning about standing right below the lifted
loads.
Careless movement of crane

Using Winches: Fig 6
They are used to pull heavy load along the ground

• Ensure adequate capacity for winches to move the load.
• Ensure strength of winch is suitable to pull load.
• Gain sufficient knowledge about the operation of winch.
• Ascertain that the brake or ratchet mechanism is in
good condition
• Keep the hands and fingers away from the gear
wheels.
Fig 7
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Using Moving Platforms:
They are used to move heavy equipments.
• Position the platform using jack or other lifting method,

so that, the load is allowed to rest on platform.
• Attach the sling to the hook of the winch and pull the
load on the platform, until, its centre of gravity lies
between the front and rear wheels.
• When the load is fully balanced on platform, allow the Fig 8

plat form to rest on its wheels.
Using Rollers:
If the load is having irregular shape of its base or not rigid, it can
be moved along ground using rollers or round bars. Rollers used should
be of uniform size and long enough to roll over any uneven surfaces but
should be small enough to handle them easily.
The load is moved with the help of a crowbar. Slopes should not
be covered using rollers without proper braking mechanism.
1.3.3 Safety in using Tools & Equipments

Most of the works at home and work place cannot be done with-
out the help of necessary tools and equipments. Using tools and equip-
ments makes the work easier, safer and faster. Some of the works can
only be done using appropriate tools and equipments. While doing a work
using tools and equipments, care should be taken to avoid
unexpected results. Fig 9
The following are some of the points to be noted for safe working with tools & equipments:
• use right tools for right job.
• do not use damaged tools to work.
• do not handle tools or equipment with wet or greasy
hands.
• operate tools & equipments with proper lighting &
ventilation.
Fig 10
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• work with tools & equipments in a firm physical

balance.
• use personnel protective equipments (hand glove,
safety helmet, safety shoe, ear plug, shield,
goggles, etc.,) wherever necessary.
• do not operate equipments on wet & slippery
plaforms.
• when handing over sharp edged tools to others,
ensure that the person receives thehandle side of the
tool.
Fig 11
• do not leave the equipments live, when not in use.
Strictly follow the manufacturer instructions & recommended tools while handling
equipments and tools.
1.4 Fire safety

Invention of fire revolutionized the development of human society through ages. Fire is
indeed a useful thing in our daily life and work, when it is in a controlled manner. When fire is
created in unwanted location, unwanted occasion and in uncontrollable quantity, it becomes the
most disastrous thing which cause heavy damage to life and surroundings.
Fire is created by the combined action of oxygen, ignition/heat and fuel.
Oxygen: Atmospheric air contains sufficient oxygen which

can support the fire.
Ignition: An electric spark, spark from friction or impact,

excess heat can initiate a fire.
Fuel: Any flammable substance in liquid, gas and solid

forms can act as efficient fuel for
burning.
Unnecessary fire should be prevented & extinguished

immediately.
Fig 12
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Fire extinguishers Fig 13
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1.4.1 Types of Fire Extinguishers
Various types of fire extinguishers are in use. Four popularly used types are described
below.
Water Fire Extinguishers:
The cheapest and most widely used fire extinguishers. Used for Class A fires. Not suitable for
Class B (Liquid) fires, or where electricity is involved.
Foam Fire Extinguishers:
More expensive than water, but more versatile. Used for Classes A & B fires. Foam spray
extinguishers are not recommended for fires involving electricity, but are safer than water if inadvertently
sprayed onto live electrical apparatus.
Dry Powder Fire Extinguishers:
Often termed the ‘multi-purpose’ extinguisher, as it can be used on classes A, B & C fires. Best for
running liquid fires (Class B). Will efficiently extinguish Class C gas fires, BUT BEWARE, IT CAN BE
DANGEROUS TO EXTINGUISH A GAS FIRE WITHOUT FIRST ISOLATING THE GAS
SUPPLY. Special powders are available for class D metal fires.
Warning: when used indoors, powder can obscure vision or damage goods andmachinery. It is
also very messy.
CO2 Fire Extinguishers:
Carbon Dioxide is ideal for fires involving electrical apparatus, and will also extinguish
class B liquid fires, but has NO POST FIRE SECURITY and the fire could re-ignite.
Wet chemical
Specialist extinguisher for class F fires.
For Metal Fires: A specialist fire extinguisher for use on Class D fires - metal fires such as sodium,
lithium, manganese and aluminum when in the form of swarf or powder.
Colour Coding
Prior to 1st Jan 1997, the code of practice for fire extinguishers in the UK was BS 5423, which advised
the colour coding of fire extinguishers as follows:
Water - Red-
Foam - Cream
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Fig 14 Safety symbols
Mandatory symbols of general Prohibition symbols

safety
wear head wear eye wear hearing

protection protection protection
Smoking and naked Do not Pedestrains
flames prohibited extingiush with prohibited
water
wear foot wear

Information signs
wear hand
protection protection respirator
shape square or oblong.
colour white symbols on
green background.
Meaning Indicates or gives
wear safety use adjustable wash hand
belt
information of safety provi-
guard
sion.
Fig 15 Example First aid
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Dry Powder - Blue
Carbon Dioxide (CO2) - Black
Halon - Green (now ‘illegal’ except for a few exceptions such as the Police, Armed Services and Aircraft).
Warning signs:
Fig 16
1.4.3 General procedure to be adopted in the event of fire
• Raise an alarm, by raising your voice and shout “Fire! Fire!” to call the attention of
others.
• Run towards fire alarm/bell to actuate it .
• On receipt of the alarm signal:
o Stop working and turn off all machinery and power.
o witch off fans/air circulators/exhaust fans. (Better switch off the main.).
• If not involved in fire- fighting:
o Leave calmly using the emergency exit.
o Evacuate the premises.
o Assemble at a safe place along with the others.
o Get someone inform about the fire break to the concerned authority.
o Close the doors and windows, but do not lock or bolt.
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• If involved in fire fighting:
o Take/give instructions for an organized way of fighting the fire.
o If taking instructions, follow the instructions, and obey, if you can do so safely; do not risk of
getting trapped.
o If giving instructions, assess the class of fire, and arrange for sufficient assistance and inform
the fire rescue service personnel.
o Locate locally available suitable means to put-out the fire.
o Judge the magnitude of the fire.
o Ensure emergency exit paths are clear of obstructions.
o Evacuate. (Remove explosive materials, other flammable materials, fuels etc.)
o Fight out the fire with assistance to put it out, naming the person responsible for each activity.
• Report the fire accident and the measures taken to put out the fire, to the authorities concerned.
1.5 Electrical Safety

Safety is a general term used for representing a condition of not having any risk of accidents.
Electrical safety is a term used to represent a condition of not having any potential risk due to different
effects of electricity. It is a fact that electricity, when used with proper care and method, provide us with
enormous benefits which can simplify and help our day to day activities. Electricity is familiar and
a necessary part of everyday life, but electricity can kill or severely injure people and cause damage to
property. It can be a cause for hazards if not dealt with care. Some of the common causes of accidents
due to electricity and its effects are listed below:
Causes:
• Improper use of machinery or apparatus.
• Use of damaged or worn out cables and power chord.
• Poorly maintained apparatus, outlets, and electrical equipments.
• Usage of equipments or cables with deteriorated insulation.
• Use of a bent or broken prong on a plug.
• Incorrect size of fuse wires.
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• Overloaded circuit.
• Placing flammable fumes near electrical apparatus.
• Use of metal tools near energized conductors.
• Dangling jewelry near an energized conductor.
• When water spills over electrical equipment
• When someone is working in a circuit with both hands.
Effects:
• Electrocution or getting electrical shock
• Electrical short-circuit causing generation of spark and heat leading to fire.
• Damaging the equipment.
1.5.1 Electrocution or electric shock
The physiological condition of pain and muscular sprains caused by the passage of an electric
current through the body is called electric shock. A person, who experiences an electric shock, may not
be able to control his or her muscles. In addition, muscles which are normally not controlled, such as those
of the heart, may operate abnormally. Tissue and organs may be burned so badly that wounds are cre-
ated. Even death can happen by electric shock.
How electric shock occur?
Most electric shocks are caused when people come in contact with defective power chords
or with energized instruments which are not covered . A person receives an electric shock when he
or she becomes a part of live electric circuit - when current enters the body at one point and exits
at a different point.
A person will receive an electric shock if he/she is in contact with:
• both energized conductors in a circuit.
• one energized wire and a ground and become a path between conductor and ground.
• a metallic piece that is in contact with an energized conductor and a ground.
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1.5.2 Factors affecting the severity of Electric Shock
• The amount of current conducted through the body.
• The path of the current through the body.
• The length of time a person is subjected to the current.
1.5.3 The effects of Electric Shock
Electric shock by a low current on the human body can cause a temporary mild tingling sensation
or even to death. An electric shock can injure you in either or both of the following.
Current in milli Ampere- Physiological effect
Contact of 1 sec.
_____________________________________________________________________________________________
Less than 1 mA No sensation; probably not noticed.
_____________________________________________________________________________________________
1 to 3 mA Mild tingling sensation not painful.
_____________________________________________________________________________________________
3 to 10 mA Mild pain and can not ignore.

_____________________________________________________________________________________________
10 to 30 mA Painful shock. Muscular control could be lost

or muscle contraction. Can not let go of
conductor.
_____________________________________________________________________________________________
30 to 75 mA Critical Respiratory problem due to
paralysis of chest muscles.
_____________________________________________________________________________________________
75mA to 200 mA Intense pain,impaired breathing, Ventricular
Fibrillation, if continued could be fatal.
_____________________________________________________________________________________________
Over 200 mA Sustained ventricular contraction followed by

normal heart rhythm. Chest muscles clam the
heart and stops it for the duration of shock.
_____________________________________________________________________________________________
Over 1 A Severe burns, internal organs burned, Death
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* A severe shock can stop the heart damaging it or the breathing muscles, or both.
* The heating effects of the current can cause severe burns, especially at points where
the electricity enters and leaves the body.
Other effects include severe bleeding, breathing difficulty, and ventricular fibrillation.
In addition, quick reflexes as a result of a shock can cause some other accidents.The
physiological effects caused in a human body by the passing of current are given in the table
shown in figure:
Typical Resistance of human body
Dry skin 100,000 to 600,000 Ohms
Wet skin 1,000 Ohms
Hand to Foot 400 to 600 Ohms
Ear to Ear 100 Ohm
1.5.4 Things to do if some one is electrified?
 If the victim is still in contact try to remove the person from contact. But do not try to touch
the person or you may be electrified as well.
Turn off the power of the device that is causing
the electric shock. If this can be done safely for
example, turning off the circuit breaker for the out
let in which the device.
 If immediate switching off is not possible obtain

an insulator, such as a wooden meter stick, and
break the contac t between the person who is
being electrified and the energized conductor.
 Otherwise, stand on some insulating material like

rubber or wood to insulate you from round and try
to push or pull the person under electric shock.
 If the victim is unconscious but breathing, then

loosen the clothing about the neck, chest and waist Fig 17
to give first aid.
 If the victim is unconscious, heart beating, but not breathing, immediately start artificial
respiration.
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DO NOT GIVE THE UNCONSCIOUS PERSON WATER OR

ANYTHING IN MOUTH AND DO NOT LEAVE HIM/ HER UN-ATTENDED
1.5.5 First Aid for affected electric shock
There are many methods for giving artificial respiration and any one method can be followed
depending upon the necessity and requirement. Some methods are:
1. Nelson’s arm method
2. Schafer’s method
3. Mouth to mouth method.
1. Nelson’s arm-lift back-pressure method:
 Remove the victim from the conductor
 Loosen the tight clothing, if any
 Place the victim laid down on chest with face looking downwards and arms folded and p a l m s
one over other and head resting on his/her cheeks resting over palms.
 Place your hands on victims back beyond the line of the armpit.
 With fingers, spread outwards and downwards.
 Press steadily the victims back with your straight arms to force the air out of the victim’s lungs.
 Move backwards, and slide your hands downwards along the victim’s arms and grasp his/her
upper arm just above the elbows as shown.
 While moving backwards, gently pull the victims arms towards you till there feels a tension,
and then lower the victims arms again to initial position.
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Fig 18
2. Schafer’s method
If the injuries are not on chest and belly
 Lay victim on his belly, one arm extended directly forward, the other arm bent at the elbow
and with the face turned sideward and resting on the forearm.
 Kneel aside the victim, so that his/her thighs are between your knees and with your fingers
and thumbs positioned as shown.
 Keeping your arms straight swing forward slowly so that a light pressure is gradually applied
to the lower ribs of victim’s body to force the air out of his lungs.
 Then swing backward immediately removing all the pressure from the victims body as
shown allowing the air to enter into the lungs of victim.
 After two or three minutes, swing forward again to push the air out of the lungs and continue the
process until the victim starts to breath.
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Fig 19
3. Mouth- to mouth method:

 Loosen the tight clothing
 Lay the victim on his back and place roll of clothing under the shoulders such that the head
is thrown back and chin straight upward.
 Grasp the victim’s jaw as shown and raise it upward until the lower teeth are higher than
the upper teeth.
 Maintain a jaw position throughout artificial respiration to prevent the tongue from blocking the
air passage.
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 Take a deep breath and place your mouth over victim’s mouth as shown making airtight
contact. Hold the victim’s nose shut with fingers.
 Blow into victim’s mouth until his chest rises.
 Remove the mouth and release the hold on the nose to let him exhale.
 Repeat the process 8 to 10 times as rapid as the victim responds.
Fig 20
1.5.6 Cardiac Arrest
 Lay the victim on his back.
 Kneel aside facing the victim, locate the lower part of the breastbone.
 Place the palm of one hand on the centre of the lower part of the breast bone and cover the
palm with your other hand locking the fingers of both hands.
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 Keeping your arms straight, press sharply down

on the lower part of the breast bone, then
release the pressure.
 Repeat for 15 times at a rate of at least once per

second.
 Check for pulse at carotid of neck.
 Give mouth- to –mouth respiration for two breaths.

Fig 21
 Again repeat another 15 compressions on heart followed by two mouth-to-mouth breathing.
 As soon as heart beat returns, stop the compression and continue respiration until natural
breathing is fully restored.
 Get medical help quickly.
1.5.7 Precautions t o prevent shock
 Get an up-to-date diagram of the working area & equipment and use it.
 Look for any electrical wires, cables or equipment near where you are going to work and
check for signs warning of dangers from electricity, or any other hazard.
 If digging or disturbing the earth or cutting into surfaces, use a cable locator to find buried
lines and mark the position you find.
 Work away from electrical wiring wherever possible. If you have to work near electrical
wiring or equipment, ask for the electrical supply to be turned off.
 Try to avoid work on live mains, and make sure that, the power is off, and it should
be kept off until your work is over.
 If the electrical supply cannot be turned off, consult a competent person who should
be able to advise you on the best way to proceed.
 Make sure that your hands or feet are not wet and are protected with rubber gloves
and shoes.
 Always ensure that you are standing on an insulated platform when working with high
voltages.
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 Also keep your left hand in pocket to avoid its contact with any live conductor
or metallic casing
 Identify where it is safe to work.
 Put up danger notices where there are still live electrical circuits,
 Remember to remove notices at the end of the work.
1.5.8 Precautions for safe operation of electrical systems
 Check for broken conductors, switches and plugs; replace them with new ones.
 Always avoid overloading of connectors and conductors.
 Check frequently for any insulation failure.
 Ensure correct rating of fuse / breaker is connected for installations.
 If possible, avoid conductors passing through the water or wet area.
 Regular preventive maintenance check for important equipments.
 Sufficient clearance from ground for over head lines.
 Check for proper earthing connections for metallic parts.
1.5.9 General precautions for Eectrical Safety
1. Care in handling all electrical apparatus and equipments is the only effective safe guard
against injury and death.
2. Never use appliances or tools that have damaged or frayed leads.
3. Replace immediately the broken switches and plugs
4. Check all that metallic parts of electrical equipment are effectively earthed.
5. Never place bare wires of leads in plug. Fit a plug top.
6. Check for proper working of safety devices.
7. Ensure proper condition of electrical hand tools.
8. Check for correct rating of fuses.
9. Never tamper unnecessarily with any live apparatus.
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Do it yourself !
 Collect the data from the locally available auditorium or theatre regarding the types of
fire extinguishing systems adapted and discuss.
 Discuss about the safe methods for lifting a 50 kg weighing motor into a truck.
 Discuss about any incident of occurrence of fire and discuss about its possible causes
including electrical systems.
Questions :
1. What are the possible accidents while lifting and handling of heavy loads?
2. What are the precautions to be taken when lifting and handling of load?
3. What are the safe methods of moving heavy loads?
4. What are the safety measures in using tools and equipments?
5. What is fire?
6. What are the essential elements to have fire?
7. What are the major three types of types of fire?
8. What are the major three classes of fire extinguishers?
9. What is the general procedure to be adopted in the event of fire?
10. What is meant by electrical safety?
11. What are the causes of electrical hazards?
12. What is meant by Electrocution or electric shock?
13. How can electric shock occur?
14. What are the three factors affecting the severity of electric shock?
15. What are the precautions to be taken to prevent electric shock?
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Chapter-2
BLOCK I
BASICS OF ELECTRICITY
Objectives:
1. Introduce the term ‘electricity’.
2. To understand the terms –voltage, current and resistance.
3. To study the Ohm’s Law.
4. To know the difference between conductors and insulators.
5. To understand the features of series and parallel circuits.
6. To understand the types of electric supply- AC and DC.
7. To identify the polarity of electric supply.
8. To know about the terms ‘electric power and energy’.
9. To learn about energy star rating.
Note to the teacher
• Display voltmeter, ammeter, multimeter, rheostat, switch, conductor & insulator materials,
cells, bulb etc. in the class room along with concerned topics.
• Give the necessary circuit in appropriate places according to situations.
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2.1 Introduction to Electricity

We use electricity for our daily needs. Without using electricity, it is difficult to live even
for a single day. Therefore, it is important for us to know some basics about electricity, its
terminology, how to measure electricity ,etc. In this chapter, we will explore the basic concepts
and terminologies related to electricity. The main terms associated with electricity are as follows:
• Current
• Voltage
• Power
• Energy
• AC and DC Electricity
We can easily understand electricity and its related terms, such as voltage, current and
power by considering an analogy with the flow of water from a tank. The flow of current in a
circuit and the flow of water from a tank have several similiarities. When the tank is filled and the
tap is opened, water flows out from the tank. Water flows out faster if a tank is fully filled as
compared to the case when the tank is partially filled. Similarly, in an electrical circuit, the current
flows when there is a voltage. Greater amount of current flows when the voltage is higher.
Therefore, the height of the water in a tank is similar to the voltage in the electrical circuit.
Water flows in terms of the flow of water molecules. Similarly, current flows due to the
flow of electrons as shown in fig. 2.1. Thus, the flow of current is the flow of electrons in an
electric circuit. Electrons are charged particles.
Therefore, in electrical terms, the flow of charged particles is defined as current flow.
High
level
Less
Tank flow Tank B
A
Fig 2.2
Fig 2.1
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35
Fig 2.3 (b) ammeter
Fig 2.3 (a) Measuring current
Voltage
The term voltage signifies the pressure (Potential difference) on electrons to flow in the circuit. The
symbol used for voltage is ‘V’. The unit of potential difference is ‘volt’. But how do we create this
“electrical pressure” or voltage to generate electron flow?
There are many sources of electro motive force (emf). Some of the more common ones are:
batteries, generators, and photovoltaic cells.
Voltmeter is an instrument used to measure voltage in a circuit and its terminals should be connected
in parallel with the source or at the points between which the voltage is to be measured as shown in fig.
2.4(a) anbelow.d 2.4(b) below.
Fig 2.4 (a)Digital voltmeter, source and load Fig 2.4 (b) Voltmeter
2.2 Resistance
The flow of current requires a medium. In the case of electrical current, the medium is
conducting wires like Copper and Aluminium.Normally, the conducting wires are chosen to
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allow the smooth flow of current, but due to their material properties, all the conducting media
possess some opposition to current flow. The amount of opposition in the path of current flow
is given by the term resistance, which is represeted by symbol, R. The resistance is measured in
Ohms. Symbol of Ohm is a Greek alphabet Omega,  .
Resistance can be both good and bad. If we are trying to transmit electricity from one
place to another through a conductor, resistance is undesirable in the conductor. Resistance
causes some of the electrical energy to turn into heat and so some electrical energy is lost along
the way. However, it is resistance that allows us to use electricity for heat and light. The heat that
is generated from electric heaters or the light that we get from light bulbs is due to
resistance.
2.2.1 Conductors And Insulators:
Conductors
Conductors are materials which readily allow the flow of electricity. Copper is considered to be
a conductor because it “conducts” current easily. Most metals are considered to be good
conductors of electrical current. Copper is just one of the more popular materials that are used for
conductors. Most of the metals have free electrons in its outer shells in the room temperature
itself, making them good condctors.
Other materials that are sometimes used as conductors are Silver, Gold, and Aluminum.
Copper is still the most popular material used for wires because it is a very good conductor of
electrical current and it is fairly inexpensive when compared to gold and silver. Aluminum and most
other metals do not conduct electricity quite as good as copper.
Insulators
Insulators are materials which do not allow the flow of electricity. Insulators are used to protect
us from the dangerous effects of electricity flowing through conductors. Sometimes the voltage in
an electric circuit can be quite high and dangerous. If the voltage is high enough, electric current
can be made to flow even through other materials that are generally not considered to be good
conductors. Human bodies will conduct electricity. Electicity flowing through the body will cause
injuries. Therefore, we need to shield our body from the conductors that carry electricity. The
rubbery coating on wires is an insulating material that shields us from the conductor inside.
2.3 Ohm’s Law
There is an important mathematical relationship between voltage, current and
resistance in electric circuits called “Ohm’s Law”. A physicist George Simon Ohm published
this formula in 1827, based on his experiments with electricity. This formula is used to
calculate electrical values so that we can design circuits and use electricity in a useful manner.
Ohm’s Law states that at constant temperature, the current flowing through the conductor is
directly proportional to the potential difference between it ends.
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Fig 2.5
In the formula, I = V/R, Ohm’s Law tells us that the electric current in a circuit can be
calculated by dividing the voltage by the resistance. In other words, the current is directly
proportional to the voltage and inversely proportional to the resistance. So an increase
in the voltage will increase the current as long as the resistance is held constant. Alternately, if
the resistance in a circuit is increased and the voltage does not change, the current will de-
crease.
2.4 Basic Electric Circuit
A basic electric circuit contains a source of electrical energy, a load which changes
electrical energy into a useful form of energy and a switch to control the energy delivered to
the load.
Source:- Source is the device which supplies the electrical energy used by the load. It may
consist of a simple dry cell, a storage battery, or a power supply.
Load:- The load is any device through which an electric current flows and which converts
this electrical energy into a more useful form. Some common examples of loads are, bulb which
changes electrical energy into light energy; an electric motor which converts electrical energy into
mechanical energy, speaker in a radio which transforms electrical energy into sound.
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Fig 2.6 Open Fig 2.7 Closed
Switch:- It permits control of the electrical device, interrupts the current delivered to the
load
The bulb does not glow when the switch is open. There is no complete path for current, (I)
through the circuit. But when the switch is closed, current flows in the direction of the arrows from
the positive terminal to the negtive terminal of the battery, through the switch, lamp and back to the
negative terminal of the battery. With the switch closed, the path for current is complete. Current
will continue to flow until the switch is moved to the open position or the battery is completely
discharged.
Depending on the connections, electric circuits are classified as series, parallel,

series-parallel etc.,
2.4.1 The Series Circuit

When loads and other equipments in an electrical circuit are connected in series as
shown below, it is called a series circuit. There is only one path for the electrons to flow . In
other words, the components, which are the battery, the switch, the ammeter, and load, are all
in “series” with each other. In a series circuit same current passes through all the loads.
Depending on the resistances of individual load, the potential drop will be different for each
load. The sum of these individual voltage drops will be equal to the supply voltage source.
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39
I1 I2 I3
Fig 2.8
In series circuit, the current flows from higher potential terminal of voltage source, then
through the protective and controlling devices and loads and then to the lower potential
terminal of the voltage source.Therefore in a series circuit,
Current I = I1 = I2 = I3, and
Voltage V=V1+V2+V3
2.4.2 The Parallel Circuit
A parallel circuit contain a voltage source, conductors, protective and controlling device and load.
The main difference between a series circuit and a parallel
circuit is in the way the components are connected. In a
parallel circuit, there will be more than on parallel path
for the current to flow from higher potential to lower.
Consider the circuit shown in fig. All the load

resistors come in parallel with the battery when the
switch is closed.
In series circuit, same current flows through all

the components at the same time. But in parallel circuit,
a part of the current pass through one load and other Fig 2.9
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part go through the other load, all at the same time. At point A, the total current splits up and take
different paths and then joins back together again at point B.
The voltage across each load is same in parallel circuit. The current component
passing through each load depends on the resistance of the individual load. Also the total current
in the circuit will the sum of individual current components passing through each load. If
the loads are bulbs in a parallel circuit, both the bulbs will glow with equal full brightness as they
get full working voltage across them. The current path in a parallel circuit is called a branch of the
circuit.
Therefore in a parallel circuit, Voltage V= V1 = V2, and Current I = I1 + I2.
Where V1 is the voltage across R1 and V2 is the voltage across R2
2.5 Types of Electric Current
Basically electric supply can be classified into two:
1. Direct Current (DC)
2. Aternating current (AC)
The type of electric current which doesnot change direction with respect to time is
called Direct current
The type of electric current which changes its direction withrespect to time is
called Alternating Current
2.5.1 Direct Current

It is the electrical quantity which does not change its direction of flow from time to time. The
battery used as a current/voltage source generates direct current, which simply means the current flows in
only one direction i.e., from positive terminal to negative (electron flows from negative to positive
terminals).
Direct current can also be generated by solar cells, generators and fuel cells.
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41
T
One cycle
Voltage v
Time t sec
Time t sec
Fig 2.11
Fig 2.10
2.5.2 Alternating Current
Alternating Current (AC) means that the direction of current flowing in a circuit is
constantly being reversed back and forth. This is done with any type of AC current/voltage
source. Ordinary domestic electric supply in most of the countries is alternating current
supply. The electric power is generated by big generators or alternators in power plants. The
direction of the current generated out of an alternator changes its direction back and forth
many times in a second. The number of cycles produced per second is called frequency (f)
of alternating current. Its unit is known as Hertz (Hz).
The consecutive positive and negative alternation is called a cycle. The time taken to
complete one cycle is known as time period (T) in seconds.
Most of our house hold electrical equipments work on alternating current. Alternating
current is more efficient than direct current in case of transmission over long distances without
losses.
When a bulb is connected in AC, the electron current is constantly reversing directions.
The change in direction of the current flow happens so fast that a light bulb does not have a
chance to stop glowing.
It is necessary to know some more quantities related to the Electrical supply system.
Two basic quantities involved are: Electric Power and Electric Energy. These are described in
the next two sections.
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2.6 Electric Power

When electricity flows in a circuit, it results in some work . For instance, when
electricity flows in a fan, the blade of fan rotates, when electricity flows in T V, the T V show
pictures, and when electricity flows in a refrigerator, it cools the things inside. What is the
speed of electrical work being done? How can we represent it ? The term, power (P), is a
measure of the rate of or speed of electrical work done.Thus, in electrical terms, how fast electrical
work done is called power. The term “power” in electrical systems incorporates both current and
voltage in it. So ,
Electric power, P = Voltage x Current
The SI unit of power is the watts (W) , or joule per second.
P = V x I (Watts)
Another example to understand the power would be two bulbs with different power ratings
as shown in fig. when compared to 60 W bulb , a 100W bulb gives more light. It means that 100W
bulb is working more than the 60W bulb. Thus, the speed of work for 100W bulb is more than
60W bulb and hence 100W bulb is more powerful.
100W
60W
Fig 2.12
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2.7 Electrical Energy

If the electrical power represents the rate or speed of work done, then the term electrical
energy presents the total amount of work done. Let’s say there are two bulbs , Bulb A & Bulb B ,
each of them are 100W power as shown in fig. Now, Bulb A is used to give us light for 5 hours
and bulb B is used to give us light for 10 hours . What is the difference in both the cases ? In both
cases, the bulb have same power each is of 100W. The difference is that bulb, A is used for 5
hours and other bulb B is used for 10 hours . So, the difference in both cases only duration of use.
The effect of time duration in electrical terms is incorporated in terms of electrical energy.In this
example bulb, B consume more energy as compared to bulb, B of same power rating. In every
electrical distribution system, to get a clear picture of the electrical energy consumption usually the
supplier provides an energy meter which clearly indicates the consumption of electricity. It is
the electric power consumed over a period of time.
Electric energy = Power (watt) x Time (hour, h)
E= P x T (KWh),
Therfore, the unit of energy (E) is Watt-hour (Wh), and large unit is KWh.
1KWh =1000Wh = 1 commercial Unit of Electric power
100W x 10h =1000Wh 100W x 5h =500Wh
Fig 2.13
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Some Equipments That Work With Electricity

Electricity has a very large influence on our lives. It is used to power many of the
things that we use every day. Below are some of the things that use electricity.
Fig 2.13 Room Air Conditioner

Fig 2.12 Fridge
Fig 2.14 Table top grinder
Fig 2.15 Air cooler
Fig 2.16 pump set

fig 2.17 submersible pump
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45
Fig 2.19 ceiling fan
Fig 2.18 exhaust fan
Fig 2.20 iron box

Fig 2.21 Table fan
Fig 2.22 induction heater

Fig 2.23 micro wave oven
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Fig 2.25 mixer

Fig 2.24 toaster
Fig 2.26 LED bulb

Fig 2.27 Pedestal fan
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What is ENERGY STAR?

ENERGY STAR is the trusted, government-backed symbol for energy efficiency helping the
customers save money and protect the environment through energy-efficient products and practices.
The ENERGY STAR label was established to:
Reduce greenhouse gas emissions (NO2 or CO2 ) and other pollutants caused by the inefficient
use of energy; and make it easy for consumers to identify and purchase energy-efficient products that offer
savings on energy bills without sacrificing performance, features, and comfort.
Fig 2.28 Energy star rating for cooling and heating
Fig 2.29 Energy star rating
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2.8 Testing of Electric Supply and Polarity

A simple method for identifying the type of electric supply is by using a neon test lamp. A neon
glow lamp is a miniature gas discharge lamp that contains neon gas at a low pressure in a glass capsule.
Fig 2.30 (a)
+
Fig 2.31 (c) Neon lamp tested with DC and AC
Fig 2.30 (b)
The gas is composed of 99.5% Neon and 0.5% Argon. A thin region near to the
electrodes glows in these lamps, which makes them distinguishable. When a small AC or DC
current, in the order of 400 micro Amperes, is allowed to pass through the tube, it glows in
orange-red color. When AC supply is given to neon lamp terminals, both of the electrodes will
glow (each during alternate half cycles).
When driven from a DC source, only the negatively charged electrode (cathode) will
glow. The applied voltage produces positively charged neon ions and free electrons. When
the supply under test is DC, the negative electrons flow to the positive side of the circuit while
the positive ions move to the negative side. The neon ion picks up an electron at the negative
electrode changing back to normal neon gas. That process produces a photon of light which is
seen as a glow at the negative pin.
When the supply is AC, both the electrodes glow, as the changing polarity changes the
negative electrode 50 times a second. These attributes make neon bulbs (with series resistors)
a convenient low-cost voltage testers; they determine whether a given voltage source is AC or
DC, and if DC, the polarity of the points being tested.
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A voltage tester is used to test the presence of AC supply. It consists of a small neon bulb
with two insulated wires attached to the bottom of the bulb housing; each wire ends in a metal test
probe. This type of tester is always used with the supply turned ON to determine whether there is
current flowing through a wire and to test for proper grounding. To test the presence of an electric
supply, touch one probe to one wire and the other probe to the opposite wire. If the component is
receiving electricity, the neon bulb will glow. If the bulb doesn’t glow, there may be a possible
trouble is at this point.
Another low-cost type of test lamp that has only one terminal open for testing, is commonly
known as screw driver tester. When the tip of the tester is connected to a live conductor, a very
small current will pass through the user’s body to complete the circuit and the neon lamp will glow.
A neon lamp connected between the tip and the other end with its two terminals, takes very little
current to light, and thus can use the user’s body capacitance to earth ground to complete the
circuit.
Identification of polarity by DC voltmeter method
The polarity of the unknown supply ( DC or AC) can be identified by a DC voltmeter. The
DC voltmeter has positive and negative terminals marked on it. The terminal probes can be
connected to the terminals of unknown polarity. If the voltmeter shows negative reading, then
interchange the leads of the meter, so that it shows positive readings. This is the indication of a DC
supply. The polarity of supply can be identified with respect to the meter terminal polarity.
If the voltmeter reads zero value and vibrates, it is the indication of AC voltage.
2.9 Identifying phase, neutral and earth wires.

Using a neon tester, we can identify the phase as explained above. Using a test lamp, it is
possible to identify either earth or neutral conductor. In domestic installation the earth resistance is
Fig 2.32 Line Tester
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nearly 3 ohm to 5 Ohms. When we connect a large load across neutral and phase, the voltage drop
will be comparatively small than the drop, when the load is connected across phase and earth.
Activity:
 Collect different types of locally available insulating and conducting materials and
differentiate them.Monitor and tabulate the weekly consumption of electrical energy and
calculate the monthly consumption.
 Identify the places and systems where we use AC and DC power.
 Measure the AC voltage and DC voltage using voltmeter.
 Identify both Ac and DC using neon tester.
Questions:
1. What is a conductor?
2. What is an insulator?
3. What is meant by voltage?
4. What is meant by current?
5. What is meant by resistance?
6. State Ohm’s law.
7. Calculate the current flowing through the fuse for a given circuit when switch is closed.
8. What are the essential elements in an electrical circuit?
9. What are the features of a series circuit?
10. What are the features of a parallel circuit?
11. Compare series and parallel circuits.
12. For a given circuit what is the reading of voltmeter and ammeter in the circuit shown (circuit to
be given).
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13. For a given circuit what is the reading of ammeter 1. and ammeter 2 in the circuit shown
(circuit to be given)
14. What are the types of electric currents?
15. What is meant by electric power and its unit?
16. What is meant by electrical energy and its unit?
17. What is the commercial unit of electrical energy?
18. How the polarity of DC supply is identified?
19. How the polarity of AC supply is identified?
20. What is meant by energy star rating?
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Chapter 3
Joints and wiring
Objectives:
1. To know about different systems of wiring.
2. Identify and study the different joints used in electrical wiring.
3. Identify the different types wires and their current carrying capacities for house wiring.
4. Identify different accessories used in house wiring.
5. Know about the general rules related to house wiring.
6. To study about general lay out of house wiring.
Note to the teacher
Familiarize the different types of wires, accessories and tools for house wiring.
Display different types of joints available.
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Joints and wiring

For using an electrical equipment, supply has to be given to the equipment through wires or
conductors. So in most of the cases conductors or wires has to be terminated, jointed and connected.
The common techniques used for termination and jointing are crimping, soldering and making joints.
3.1 Skinning
For joining two conductors together, first their insulation is removed. The insulation of the wire
should not be cut by holding the knife at right angles to the conductor (as shown in figure a) . But it should
be removed by holding the knife at an angle just as in the case of sharpening a pencil as shown in figure.
Taking care not to injure the copper conductor. The removing of insulation in a tapered fashion is a necessisity
since it facilitates better jointing and insulating the joint. Then the insulation is pulled out by a combination
plier. The length of bare con-
ductor is approximately 2.5
cms.
3.2 Soldering
Soldering is the process
of joining metal sheet (such as
tin, galvanised iron, copper
sheet, etc.,) with an alloy
whose melting is less than that
of the materials to be
soldered. The alloy used for
joining the metals is called Fig 3.1
solder.
The most common solder is composed of 50% Lead

and 50% Tin. The composition of soft solder is 60% lead
and 40 % tin. Its melting temperature is 190 degree celsious.
For proper soldering, flux is to be used. In soldering
process the application of flux serves to remove oxides
from the surface to be soldered. Uses:- It is not possible
to solder on Aluminium conductors. In order to make
termination in aluminium conductors, Crymping methods.
This method is used inorder to make termination in coppor
conductors.
Fig 3.2
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3.3 Crimping and crimping tool
Crimping is the operation of joining the terminal ends with the help of a connector lug.
Using the crimping lug connector and tool, the lug connector is firmily joined to the end of wire of
correct size.
Care and maintenance:

• Do not use it on thick steel made sleevers or lugs.
Fig 3.3(a)
Fig 3.3(b)
3.4 Joints in Electrical conductors
A joint in an electrical conductor means connecting or tying or tapping of two or more
conductors such that the union/junction becomes both electrically and mechanically secured.
Joints in electrical conductors are necessary to extend the cables, overhead lines, and
also to tap the electricity to other branch loads wherever required. As per the requirements
different types of joints are used. Some of them are:
1 Pig Tail or rat-tail or twisted joints
2 Married joints
3 T- Joints
4 Western Union joint
5 Britannia straight joint
6 Britannia T- joints
7 Tap joints in single stranded conductor
8 Scarfed joint
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1. Pig-tail/Rat-tail/Twisted joint
This joint is used where there is no mechanical

stress on the conductors. They are usually used in
junction boxes or conduit accessories boxes. The joint
should have good electrical conductivity.
Fig 3.4
2. Married joint
A married joint is used where appreciable

electrical conductivity with compactness is
required. The mechanical strength is less and so it
cannot be used where there is more tensile stress
Fig 3.5
3. Tee joint
This joint is usually used in overhead

distribution lines where the electricity is tapped
for service connections.
4. Western union joint Fig 3.6 Tee Joint
This joint is used in overhead lines for

extending the length of wire where the joint is
subjected to considerable tensile stress.
Fig 3.7 Western union joint

5. Britannia straight joint
This joint is used in overhead lines where

considerable tensile strength is required. They
are usually used for inside and outside wiring
where conductor of diameter 4 mm or above is
used.
Fig 3.8 Britannia Joint
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57
6. Britannia Tee joint
This joint is used for overhead lines for tapping

the electricity perpendicularly to the service lines.
Fig 3.9 Britannia tee joint

7. Tap joints
A tap is a connection of the end of one wire to some point along with another running wire.
There are different types of taps like plain, aerial, knotted, cross-double-duplex.
A. Plain tap joint
This joint is the frequently used and simple one, which can be quickly made.
Fig 3.10 Plain tap joint
B. Knotted tap joint
Fig 3.11 Knotted tap joint
C. Duplex cross-tap joint
Fig 3.12 Duplex cross tap joint
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8. Scarfed joint
This joint is used in large single conductors where good appearance and compactness are
the main considerations and where the joint is not subjected to appreciable tensile stress.
Fig 3.13
Fundamentals of Electrical Wiring
Electrical wiring in buildings and other installations are meant for supplying electrical power
to different equipments and machines which runs on electrical energy. The essential components
in a wiring system are: supply source, conductor, fuse and a control switch. The electrical energy
flows from the source to the load, through the conductors, controlled by the switch and protected
by the fuse.There are some standards specified for wiring an electrical system taking into account
the safety aspects of handling the electricity.
Fig 3.14
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59
The source of electrical energy in a house hold or other location generally is the electrical
power supplied by the Electricity Boards. In India, state Electricity Boards are the authorities to
generate and distribute electricity. Electricity Board provides the domestic electrical power with a
voltage of 230 V AC in single phase systems.
A network of wires connects various accessories for the distribution of electrical energy
from the supplier’s meter board to number of electrical equipments like lamps, fans and other
domestic appliances through controlling and protective devices is known as wiring system.
The Electricity Board’s service cable terminates in the service fuses. In an ordinary house
the service fuse is called as service cutout. Such cut-outs including service energy meters are the
property of the supplier and represent the last point of the supplier responsibility.
The point at which the consumer’s wiring is connected into cutout is known as point of
commencement of supply or consumer’s terminals. From consumer terminals onwards the supply
cables are entirely under the control of consumer’s and so laid out as per his selection.
The energy meter is connected after the IC cut-out in olden times. Now a days, it is
connected immediately to the service mains.
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Fig 3.15
Fig 3.16 Fig 3.17

ELECTRONIC ENERGY METER MECHANICAL ENERGY METER
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61
Systems of distribution
Since as per recommendations of ISI, the maximum number of points of lights, fans and
socket-outlet that can be connected in one circuit is 10 and the maximum load that can be connected
in such a circuit is 800 watts, in case more load or more points are required to be connected to the
supply system, then it is to be done by having more than one circuit.
Distribution system
In this system, mains are taken to one or more distribution centres and connected to the
distribution board. From those distribution board connection to the branch circuit are taken. In this
system no joints are required. Each circuit can be redily disconnected from the main wihout inter-
fering the other circuits. This system is now a days widely used in indoor wirings in buildings.
Advantages are:
i) Appearance is good.
ii) Fault location is easy.
iii) All the points are maintained almost at the same voltage.
iv) Each circuit is protected by a fuse.
v) Replacement of fuse is easy.
vi) This system is simple and capable of further extention.
Disadvantage:
More wire will be required to install the system, So its cost is greather than the tree system.
Tree system
In tree system, branch circuits are taped from the circuit main at convenient places. In this
system, there are many joints and often fault occurs. which is very difficult to locate. This system
is not used for installation purpose. its advantage is less cost. Disadvantages are:-
a) Appearance is poor.
b) Fault location is difficult.
c) Voltage drop effected.
d) The fuses are scattered.
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Systems of wiring
The types of internal wiring usually employed in our country are:
1. Cleat wiring
This type of wiring is not used practically for permanent wiring and is only suitable for
temporary wiring purposes such as for marriages with advantages of saving in labour and overall
cost.
2. CTS/TRS wiring
The wires used in such a wiring are sheathed in tough rubber of PVC wires and they are
carried on wooden batten with clips. This wiring is suitable for damp climate, but canot withstand
much heat and so is not suitabl for hot weather and there is also danger of mechanical damage and
fire hazard.
3. Wooden casing and capping wiring
This is the most common type of wiring used for indoor and domestic installation. VIR wires
are carried in two or tripple channel of wooden casing and closed by wooden capping.
4. Lead sheathed wiring
In lead sheathed system the conductor either twin core, each being seperately insulated and cov-
ered with the common lead sheath is used. The lead sheathed wires are easily fixed by means of metal clips
on wooden battern and from a good surface system.
5. Conduit wiring
In this system VIR wires or PVC wires are carried through steel or iron pipes giving goood
protection from mechanical injury or fire risks. In this wiring the pipes are cut with hacksaw
and are threaded with die set. Bend, Tee, junction and box etc. are then fixed on the walls on
wooden gutties or plugs with saddles.Then wires are drawn with the help of fish wires.
Now a days PVC conduit pipes are also avilable which do not require any threading.
Jointing is done with a special made solution. They are flexible and can be bent easily.
uses:-Workshop, public buildings etc.,
General rules for wiring

There are certain rules laid down by the authorities which have to be followed strictly.
Some of The main rules are:
1. AC and DC Circuit should be separated, 3 phases should be indicated with red,
yellow,blue and the neutral should be indicated with black. in DC positive should be
indicated with red , negative with blue and neutral with black.
2. If the voltage exceed 250 V, all the DB and the mainswitches provided with danger
board
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63
3. Total load in the circuitshould not exceed more than 800 Watts and number of points
should not be more than ten.
4. Power devices should have different circuits.
5. For lighting load the fuse wire should not exceed 5 Amp. Capacity . for power, it is
10 Amps.
6. The size of the conductor should be such that the voltage drop should not increase
more than 3% of the connected voltage when full load current is flowing .
7. The minimum size of the conductor in sub circuit should not be lessthan 1/8 in case of
copper wire and 1/1.4 mm ( 1.5 sqmm) in case of Aluminium wires.
8. All Distribution Boards should be markedas power and light as the case may be.
9. All the acessory should be fixed on the round block or board with brass screws.
10. In the domestic wiring three pin only should be used
11. No inflammable shades should be used in installation.
12. All the iron clad appliances, switches, etc. should be earthed. (Ceiling Fan, Brackrt,
Brass Holder )
13. Neutral should be linked.
14. All the switches should connected through live wire
15. All the boards should be fixed at a height of 1.5 m.
16. All the fan should be fixed at the height of 9 ft. (2.5m ) from the ground.
17. All the boards and switches should be fixed on left hand side of the entrence.
18. Round block should be fixed with two screws.
19. All the switches shall be installed on the live lines only and never on the neutral. in
wiring the live line of the supply should be red, yellow or blue colour while that
connected to the neutral should be of black colour.
CURRENT CARRYING CAPACITY OF PVC INSULATED COPPER CABLES
Conductor crossional area in sq mm Current carrying capacity in Amps
1.5 20
2.5 29
4 37
6 48
10 66
16 86
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Wiring accessories
Fig 3.18
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65
(Miniature circuit breaker)
(residual current circuit breaker) (earth leakage circuit breaker)
Fig 3.19
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3 pin socket 3 pin top
Fig 3.20
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67
Lamp holder
Saddles
LED lamp
lamps
Fig 3.21
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Main switch and Distribution board
Fig 3.22
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69
ceiling rose
CFL
lamp holders
Fig 3.23
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Questions:
1. What are the 2 major different systems of wiring?
2. Explain the different types of wiring
3. What is meant by soldering?
4. What are the different types joints along with their point of application in electrical
circuits?
5. State 5 important rules for electrical wiring.
6. What are the different materials and accessories used in house wiring?
7. Make a lay-out for installation of an electrical system for house wiring from the service
mains.
8. What is the use of ELCB in house wiring?
9. What is the use of MCB in house wiring?
10. What is the use of fuse in house wiring?
Activity:
List the material for mounting a ceiling fan and identify them.
Observe and identify, which type of joint is used in domestic service connection.
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71
Chapter-4
BLOCK I
EARTHING & ENERGY METER INSTALLATION
Objectives:
1. To study about importance and need of earthing.

2. To study various types of earthing
3. To know about the factors affecting earthing
4. To know the objectives of earthing
5. To understand the schematic of energy meter installation
Notes to the teacher
 Display the different types of earthing with video or pictures

 Mention about the instrument Megger and its use
 Display and familiarize the energy meter and its terminals
 Compare the conventional and modern concepts of energy meter installation
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4.1 Earthing
Earthing means provide an easy path for electric supply to earth. Earthing of electrical system
are done by using earth electrodes which connects the electric systems to the mass
Earthing of an installation can be brought under two major categories.
(1) System earthing
(2) Equipment earthing
System earthing: Earthing associated with current carrying conductors is normally essential
to the security of the system and is generally known as system earthing.
Equipment earthing: Earthing of non-current carrying metal part and conductor which is
essential for the safety of human life, animals and property is generally
known as equipment earthing
Terminology related to earthing:
1. Earth: It is a connection to the general mass of earth by means of an earth electrode. An
object is said to be earthed when it is electrically connected to an earth electrode.
2. Earth continuity conductor (ECC): The conductor including any clamp connecting to
the earthing lead or to each other those parts of the installation which are required to be
earthed.
3. Earth current: A current flowing to earth by some fault.
4. Earth Electrode: A metal plate, pipe or other conductor or an array of conductors
electrically connected to the general mass of the earth.
5. Earth fault: Live portion of a system getting accidently connected to earth.
6. Earth terminals: A terminal provided on a piece of apparatus for the purpose of making
a connection to earth .
7. Earth wire: A conductor connected to earth and usually situated in to the associated line
conductors is called earth wire.
8. Earth pole: The Pole or line of an earthed circuit which is connected to earth.
9. Leakage: The passage of electricity in a path other than that desired due to imperfect
insulation.
10. Leakage current: A fault current of small value which is different from the short circuit
current is known as leakage current.
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73
Fig 4.1
4.1.1 Need for Earthing

An electric shock is dangerous only when the current through the body exceeds beyond
a certain milli-ampere value. In general, any current flow through the body beyond 5 mA is
considered as dangerous. However, the degree of danger is dependent not only on the current
flow through the body, but also, on the time during which it flows. In human beings, the
resistance between hand to hand or between hand and foot can easily be as low as 400 ohms
under certain conditions. So earthing is done to prevent or minimize the risk of shock to
human beings and livestock. Electrical installations have properly earthed metal part to
provide a low resistance discharge path for any fault or leakage current which would otherwise,
cause accidents.
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Case 1: When metal body is not earthed

A 240 V AC circuit is connected to an apparatus having a load resistance of 50 ohms,
and a defective insulation of cable makes the metal body live and the metal body is not earthed.
A person whose body resistance is 1000 ohms comes in contact with a metal body
which is at 240 V; a leakage current of 240 mA (240/1000) will flow through his body
and may cause severe injuries. The 5 A protective fuse in the circuit will not blow for
this additional leakage current.
Fig 4.3
Case 2: When metal body is earthed

The person will not get shock due to 2 reasons: Before the fuse operates, the metal body
and earth are in the same zero potential and across the person there is no difference of potential.
Within a short milli-second the fuse blows to open the defective circuit, provided the earth resistance
is sufficiently low.
By analyzing the above two cases, it is clear that a properly earthed metal body eliminates
the shock hazards to persons and also avoids fire hazards in the system by blowing the fuse quickly
in case of ground faults.
Fig 4.4
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75
Factors affecting the value of earth electrode resistance

• Electrode size & material.
• Material and size of earth wire.
• Moisture content of soil.
• Depth of electrode of underground.
• Quantity of dust and charcoal in earth pit.
Factors affecting Earth resistance
• Resistance of metal electrode
• Contact resistance between electrode and soil
• Resistance of soil away from electrode surface.
The resistance decreases with the presence of moisture and salt in soil. To increase the
effectiveness of earth, the total earth resistance should be reduced. Efforts should be made to
reduce the resistance contributed by each of above three components.
4.1.2 Objectives of Earthing
1. To save human life from danger or shock or death by blowing fuse of any apparatus
which becomes leaky.
2. To protect large building from atmospheric lightining.
3. To protect all machines fed from overhead lines from lightining arresters.
4. To maintain the line voltage constant.
4.2 Types of Earthing
1. Pipe earthing.
2. Plate earthing
4.2.1. Pipe Earthing:
In this method of earhing, a 38mm internal diameter, perforated galvanised pipe of length
2.5m is placed vertically in a permanently wet soil.The pipe is surronded by the pieces of coke or
charcoal and salt in alternate layers to decrease earth resistance as shown in fig. Another pipe of
19mm dia and length 1.25m is connected to the burried pipe through reducing socket. At the top of
the 19mm pipe a funnel is fitted and is fastened in a cement concrete work. For effective earthing
water should be poured through funnel particularly in summer season.
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Fig 4.5
The earth wire is carried in a GI pipe of 12.7mm dia. at a depth of 60cm from the ground
level.
4.2.2.Plate Earthing:
The electrodes are made of galvanized iron or steel or copper. The plate electrode should
have a minimum dimension of 600x600x3.15mm for copper plate or 600 x 600 x 6.3mm for G.I
plates. The plate electrode should be placed at least 1.5m below the ground level. The earth
conductor is to be securely connected to the plate by means of bolts and nuts. The bolts and nuts
should be of the same material as that of the plate. The earth conductor should be carried in a G l
pipe buried 60 cm below the ground level. The plate electrode should be surrounded by a layer of
charcoal to reduce the earth resistance. A separate GI pipe with funnel and wire mesh attached is
provided to pour water into the sump.
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77
Fig 4.6
4.3 Earthing Domestic Installations

It is necessary to make sure that nobody should be affected by electric shock. for this
make sure that :
(i) All the metal parts of the switch board is earthed.
(ii) All the metal parts of distribution box, main switch and energy meter case are earthed.
(iii) All the body of the motor, iron box , grinder , etc.,are earthed properly.
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4.4 I S specification regarding earthing of electrical installations:

1. Distance of earth from building: Earthing electrode should be at least 1.5 m away from the
system earthed.
2. Size of earth continuity conductor (ECC): The cross section of ECC should not be either
less than 2.9 mm2 or half of the installation conductor size
3. Resistance of earth: The following values are specified for earth resistance:
a. Large power station- 0.5 Ohms
b. Major power station- 1 Ohm
c. Small sub-stations- 2 Ohms
d. In all other cases– 5 Ohms (max.)
e. Earth continuity inside an installation; earth plate to any point in the installation-1 Ohm
4. Earth wire and earth electrode should be of same material
5. Earth wire connected to an earth electrode should run along the whole wiring system
6. The earthing electrode should be placed always in vertical position inside the earth pit.
7. Distance between plate earth electrodes shall be 8m minimum.
8. Distance between pipe earth electrodes shall be 5m minimum.
9. The minimumcross-sectional area of the GI should be 50 sq.mm.
10. All joints in earthing conductors shall be properly tinned.
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79
Questions:
1. What is the use of earthing?

2. What are the two systems of earthing?
3. What are the factors affecting the earth resistance?
4. Explain the procedure of pipe earthing.
5. What are the objectives of earthing?
6. Draw the energy meter connection in block diagram as per new convention.
7. What are the things to be done for earthing domestic appliances?
8. Write the permissible values of earth resistance in different situations.
Activity:
• Observe and identify the types of earthing used in your school building and your
home.
• Find out the reason for larger size of earth pin compared to other two pins used in
3 pin plug.
• Enquire about the systems used for protection about the lightening.
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81
Chapter-I
BLOCK II
SAFETY PRACTICES
1.0 To lift a heavy motor to a table using any appropriate method.

2.0 To make a fire and extiguish the fire using a suitable fire extinguisher.
3.0 Identify the safety measures you can implement in your institution.
4.0 Practice Mock treatment for a person affected electric shock .
5.0 Collect different tools used for electrical maintenance and wiring and write the
specifications.
Familiarise Tools For Electrical Work

Screw Driver
Uses:- Used for loosening or tightening or to keep screws in position
Care and maintenance:-
• Do not use in place of Firmer Chisel.
• Use proper size for particular screws.
• Avoid greasy or oily handle.
Pliers
a. Combination pliers:
Uses:- For holding, twisting or cutting wires.
b. Nose pliers:
Uses:- For holding, twisting or joining wires at narrow places.
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c. side cutting pliers:
Uses:-For cutting wire at narrow places or ordinary places.

Care and maintenance of Pliers:
• Do not cut steel wires .

• Do not hold any hot substance.
• Do not use in place of hammer.
• Protect from rust.
Electrician’s knife
Uses:- It is used for removing insulation of wires.
Care and maintenance:-

• Do not use it f or cutting wires.
• Protect from rust.
Measuring tape
Uses:-Used for measuring the dimension of wiring. It is

made of steel or cotton cloth.

• Do not shift the open tape.
• Avoid from rust.
Wire stripper & cutter

Uses:-These are used for removing insulation of wires.These are available with adjustable 22 SWG and
onwards.
• Use proper stripper or cutter for particular wire.
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83
Electric Soldering Iron
Uses:-To solder the joints of wires and winding wires.

• While using insulate yourself.
• Do not put hot iron on wires.
Ball peen hammer

Uses:-Best suited for chipping on teak wood batten, and
rivetting purpose in sheet metal works. And used for
fixing clip and making gutties hole in wall.
• Never use loose handled hammer.
• Hammer handle should not be greasy.
Cold Chisel
Uses:-Used for chipping, boring and channeling in walls.
• Should not be oily.
• Avoid flat heat.
Try square
Uses:-To check the right angle of corners
• Do not use as hammer.
• Keep it safe, avoid rest
Poker
Uses:-Used for making piolet holes for fixing wood screw.

• Should not be used on metals.
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Rawal plug tool

Uses:-Made of steel and is used for making holes in the stone wall or c oncrete wall for fibre made
rawal plugs.

• Do not throw it on the ground.
• While using rotate it slowly.
• Do not use it on metals.
Hack saw
Uses:-Used for cutting conduit GI pipe or mild steel.
• Keep straight while cutting.
• Keep safe from rust during storing.
• Apply water on blade while cutting.
Files
Uses:-To smooth the surface or corners of any iron board etc.
• Do not use without handle.
• Do not use it as hammer or screw driver or poker.
Crimping tool
Uses:-As soldering on aluminium conductors difficult, this
is used to crimp the joint or lugs.
• Do not use it on thick steel made sleevers or lugs.
Neon tester
Uses:-Used to find supply in live conductor or system.
• Do not drop it.
• Do not use it as screw driver.
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85
Chapter-II
BLOCK II
BASICS OF ELECTRICITY
1. MEASUREMENT OF RESISTANCE
Objective:
To measure the resistance of the load resistor.
Materials required:
1.Power supply 0-30V, 2A
2. Rheostat 50 Ohm , 2A
3. Voltmeter 0-30V
4. Ammeter 0-2A
Connection diagram: (0-1A)
S
+ A _
+
+
_ V 0-30V 50 Ohm, 2A
30V,2A D C
_ Rheostat
Procedure:
1. Identify the voltmeter from the dial marking V

2. Identify the ammeter from the dial marking A
3. Identify the fixed and variable terminal of the rheostat and connect two fixed terminals
in the circuit to get constant resistance.
4. Connect the circuit elements as shown in fig.
5. Close the switch and apply different voltages by variable power supply.
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6. Meaure the voltages and corresponding current from the instruments.

7. Record the measured value in table
Observation
Resistance in
SL NO Voltage in V Current I(Amps) Ohms
1
2
3
Sum
Average Resistance = (sum of resistance / no of readings ) in Ohms

Sample Calculation:
Voltmeter reading ......... Volts
Ammeter reading ......... Amps
Therefore, Resistance = V/I Ohms
= ....... / ...... Ohms
= ........ Ohms
Result:-
The value of the unknown resistance is the average of all the resistance obtained from the table.
Resistance = ..............................Ohms
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87
2. CONNECTING LAMPS IN SERIES

Objective:
1. To connect lamps in series.
2. To observe the voltage across each lamp and verify total voltage equal to sum of
the indi vidual voltage drop.
3. And to verify current is same in a series circuit.
Equipments required
1. DC Regulated Power supply, 30V, 2A 1No

2. 6V, 1W bulb - 1No
3. Voltmeter 0-30v 4 Nos
4. Ammeter 0-1a 1No
Connection diagram
1. Form a circuit as shown in above figure.

2. Switch ON power supply and set voltage as 18V because the lamps are 6V rating (3 X
6=18V)
3. Close the switch S1 and measure the voltmeter and ammeter readings.
4. Enter the measured value in table.
5. Repeated the process by varying the power supply.
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V V1 V2 V3 V=V1+V2+V3 I
Sum of voltages across each load V = V1 + V2 + V3 = ..... volts

Applied voltage = ....... volts
There fore, applied voltage = sum of the voltage drops across the load
Result:
In series circuit the applied voltage to the circuit is droped across each load according to its
resistance.
1. Obtained a series circuit
2. V = V 1 + V2 + V3
3. Verified and found that the current is same in a series circuit.
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89
3. CONNECTING LAMPS IN PARALLEL
Objectives
1. To connect lamps in parallel.

2. To observe the current in different branches and verify total current is sum of individual
branch current.
3. And to measure the voltage across each branch in the parallel circuit.
Equipments required
1. Power supply 30V, 3A

2. Voltmeter 0-15V 1 No
3. Ammeter 0-1 3 Nos
4. Ammeter 0-3A 1 No.
Connection diagrram:
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Observation
V I II 12 13 I=II+I2+I3
Sum of branch currents = I1 + I2 + I3 = ...... Amps

Total currents, I = ....... Amps
There fore, total current , I = sum of branch currents
Procedure:
1. Form a circuit as shown in fig.
2. Switch ON power supply and set voltage as 12V.
3. Close the switch S1
4. Measure the voltmeter and ammeter readings.
5. Enter the measured value in table.
Result:
In a parallel circuit, the sum of branch current will be equal to the total current. The voltage
across each branch is remaining the same.
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91
4 TESTING THE POLARITY OF DC SUPPLY

Objective:
Aim: To identify the polarity of a DC supply:
Equipments & materials required:

Battery, Voltmeter, Multi-meter, neon lamp, connecting wires, etc.
Procedure:
1. Identify the terminals of a battery. Positive and negative terminals will be marked in most of the
cells with ‘+’ or ‘-‘ signs. as shown in fig.1 and also shown positive terminal by red colour and
negative by blue or black colour.
2. In the case of two wires coming from a DC source, it can be identified using a DC voltmeter or a
multimeter. Connect the voltmeter such that it shows positive deflection, then the supply terminal
connected with the positive of voltmeter is in the positive polarity and the other supply terminal
will be in the negative polarity.
+
V VOLTMETER
- -
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5. TESTING THE POLARITY OF AC SUPPLY

Objective
To identify the polarity of an AC supply:
Equipments & materials required:

AC supply source, multimeter, neon lamp tester, connecting wires, etc.
Procedure:
The polarity of AC supply can be identified by using a simple neon lamp. When we
connect any terminal of AC supply to neon tester, if the tester glows, the supply terminal is called live
line or phase. The other terminal which when connected to neon tester does not glow is the neutral
line.
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93
6. VERIFICATION OF AC POWER SUPPLY (SOCKET)

POLARITY
Warning: Only trained professionals should test mains voltage polarity.
Equipment needed: Multimeter capable of measuring 250 V AC
Instructions for testing with multimeter
1. Set the multimeter to test AC voltage for 230 V AC or higher.

2. If the socket has a power switch ensure that this is active.
3. Using the multimeter probes measure the potential between the Live (Phase) and earth.
The expected value should be 230V AC (nominal).
4. Using the multimeter probes measure the potential between the Neutral and Eartth
conductors. The expected value should be about 0V AC (can vary depending on the
type of the earth consirions).
5. The potential between the Live and Earth is about 230V AC and the potential between
the Neutral and Earth is about 0V AC.
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95
Chapter-III
BLOCK II
JOINTS AND WIRING
1. SKINNING
Objective:
To remove insulation of a cable tip by skinning
Tools & materials required:

Electrician’s knife, 1.5 sq. mm wire -400 mm, steel rule, combination pliers
Procedure:
1. Mark the length of 1.5 sq.mm cable at 400 mm from its end
2. Cut the cable using a combination pliers at the mark
3. Mark the length of the insulation to be skinned from either end
4. Remove the insulation of the cable for about 10 mm. at its ends using the knife as
shown in figure.
5. Keep the knife blade at an angle of about 20 deg. to the cable
6. Ensure that there is no nicking over the conductor
7. Clean and verify the surface of the bare conductor for correct skinning
8. Repeat the skinning for other cable sizes and for other lengths.
Fig 1
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2. CRIMPING
Objectives:
Crimping of lug connector
Materials and tools required:
Wire stripper,
Crimping Pliers (150/200 mm),
Steel rule,
Type of crimping lug 6A/10 A/16 A, IS 8308/8309,
Multi strand wire 25 sq. mm,
Oxide inhibiting grease-10 g.
Fig 2
Procedure:
1. Take the wire and strip off the insulation to suit the terminal size of spade
connectors by using wire stripper.
2. Twist the strands of the lightly in the same direction as in the original.
3. Clamp the spade crimping lug in the matching position between the jaws of the
crimping tool.
4. Insert the prepared wire end far enough in the tube portion of the spade crimping lug.
5. Apply light pressure to create a light impression on the centre of the tube portion
of the lug connector.
6. Check whether the press is located in the middle of the lug connector and if found
correct, apply sufficient pressure in the handle of the crimping pliers to press the
connector fully.
7. Verify crimping quality by inspection and by shaking the cable from the lug connector.
8. Repeat the crimping of lug connectors of various sizes and different lengths.
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97
3. STRAIGHT JOINT
Objective:
To make a straight joint out of two single stranded wires.
Materials & tools required:
Electrician’s knife, steel rule, combination pliers, PVC insulated, 1.5 sq. mm single stranded
copper wire-500 mm length, or use aluminium wire 2.5 sq.mm.
Fig 3
Procedure:
1. Make two pieces of cable with 250 mm length.

2. Straighten the cables, mark 80 mm length on one end of each cable.
3. Use the knife at an angle of 20 deg. and remove the insulation of each conductor for a
distance of 80 mm.
4. Clean the ends and place the conductors together about 50 mm from the ends as
shown(fig).
5. Twist them tightly around each other in the opposite directions.
6. Make around 6 nos. of turns and cut off the excess lengths.
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4. MARRIED JOINT
Objective:
To make a married straight joint out of two multi stranded wires

Electrician’s knife, steel rule, combination pliers, PVC insulated, 1sq. mm multi-
stranded copper wire-500 mm length
Procedure:
Task :prepare a married joint in stranded conductors as shown in fig.1
1. Make two pieces of cable with 250 mm length.
2. Straighten the cables, mark 120 mm
7. Hold one of the cable in one hand and twist the strands of the other cable end over it-
one by one, closely and tightly, half turn for each strand
8. Remove the binding made before on the twisted portion.
9. Repeat the twisting operation for the other cable side.
10. Check the joint for correctness and complete the joint as shown in fig.1
Fig.1
Fig.2
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99
5. TEE JOINT
Objective:
To make a Tee joint out of two multi stranded copper wires
Electrician’s knife, steel rule, combination pliers,

PVC insulated, 1sq. mm multi- stranded copper
wire-500 mm length
Procedure:
Fig 5
1. Make two pieces of cable with
250 mm length.
2. Straighten the cables; mark the point
of tap in the through cable at 60 mm
in each side from the centre.
3. Remove the insulation of 120 mm
Fig 6
marked length of through cable by
knife.
4. Remove the insulation for 180 mm of tap cable.
5. Open the strands of the tap cable and re twist the strands in the original direction up to
50 mm from the insulation.
6. Make a binding on the twisted parts of the tap cables as shown (fig)
7. Untwist the through cable to provide an opening at the point of tap.
8. Insert the middle strand of tap cable in the opening made in the through cable as shown.
9. Wrap 3 strands of tap cable around the through cable on either sides of tap point to form
a shoulder on the through cable.
10. Wrap the strands up to 50 mm to lave a 10 mm gap between the insulation and shoulders.
11. Trim off the excess length of strands.
12. Remove binding from the tap cables and wrap the centre strand of the tap cables in the
place of removed binding.
13. Round up the ends with combination pliers or mallet to avoid sharp edges.
14. Check the Tee joint for correctness.
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Fig 7
Fig 8
TEE JOINT
Fig 9
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101
Chapter-IV
BLOCK II
EARTHING AND ENERGY METER INSTALLATION
1. PREPARE THE LIST OF MATERIAL REQUIRED FOR PIPE
EARTHING
Sl. No. Specification of material Qty.
1. 38 mm dia. G.I pipe (perforated) 2.5m
2. 19mm dia. G. I pipe 1m
3. 12.7mm dia. G. I pipe 2m
4. G.I wire 8 SWG 6m
5. G.I (38-19mm) reducing socket 1No.
6. G.I lugs 2No.
7. Nuts bolts, locknuts and washers for 19mm dia. conduit 2sets
8. G.I bends 12.7 mm 2No.
9. 30 30 cm cast iron frame with hinges. 1No.
10. 30 30cm cast iron cover 1No.
11. Funnel with wire mesh 1No.
12. Charcoal or coal pieces 20Kg.
13. Salt 20Kg.
14. Cement concrete Lump sum
15. Caution plate painted 1No.
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2. ENERGY METER INSTALLATION
Aim: To carry out energy meter installation
Materials and tools required:
PVC copper cable 2.5 sq. mm

Tinned copper single stranded 14 SWG
Neutral link 16 A
Teak wood board 250 X 250 X 40 mm
Steel screws 20 mm
Porcelain fuse carriage 16 A
Single phase energy meter 5-15 A, 250 V
Steel rule
Wiring practice board
Combination pliers
Screw driver
Neon tester
Chisel Fig 10
Poker
Wire stripper
Procedure:
1. Mount the wiring practice board
vertically on a wall.
2. Drill 4 through holes of 3 mm.
diameter in the teak wood board
and fix it on the wiring practice.
board as shown in figure.
3. Fix energy meter and fuse carriage
on the teak wood board. Fig 11
4. Connect the energy meter and fuse carriage as per the circuit diagram.
SITTTR Kalamassery
103
3. ONE LAMP CONTROLLED BY ONE SWITCH

100 W, 230V


15 CM
o o
 15 CM  

15 CM
FUSE
LAYOUT CIRCUIT DIAGRAM one way

switch
CONDITIONS
S1 L1
ON ON
OFF OFF
PROCEDURE
1. Mark the dimensions and positions according to the layout shown.
2. Place round blocks in the place of lamp and switch using two wood screws.
3. Fix the Kit-kat fuse using two screws.
4. Cut wires acccording to the lenth given in the layout.
5. Connect the wire in the terminals after skin it. The joints should be tight and bur
free.
6. Give supply after completing the circuit only with consent of teacher.
7. Test whether you get the conditions then disconnect as directed by the teacher.
SITTTR Kalamassery
4. ONE LAMP CONTROLLED BY TWO SWITCHES

INDEPEDENTLY
100 W, 230 V
15 CM 15 CM
oo
AC supply 15 CM 15 CM
S1 S2
LAYOUT
Two way switches

CONDITIONS CIRCUIT DIAGRAM
S1 S2 L1
ON ON ON
ON OFF OFF
OFF ON OFF
OFF OFF ON
PROCEDURE
5. Connect the wire in the terminals after skin it. The joints should be tight and bur free.
SITTTR Kalamassery
105
5. TWO LAMPS CONTROLLED BY TWO SWITCHES

INDEPENDENTLY
25W, 230V 25W, 230V
L1 L2
oo
supply
S1 S2
All dimensions are 15 CMS
S1 S2
LAYOUT
CIRCUIT
S1 S2 L2 L1
ON ON ON OFF
ON ON ON ON
OFF OFF OFF OFF
OFF ON OFF ON
CONDITIONS
PROCEDURE
SITTTR Kalamassery
6. TWO LAMPS CONTROLLED BY ONE SWITCH
CONDITIONS 100 W, 230 V 25 W,230 V
S1 L1 L2
ON ON ON
OFF OFF OFF

oo
LAYOUT One way switch
Lamp 1 should be 25W, 230V and lamp 2 should be 100W, 230V
PROCEDURE
SITTTR Kalamassery
107
7. TWO LAMPS CONTROLLED BY ONE SWITCH IN SERIES
100 W, 230V 25 W, 230V
oo
15 CM
All dimensions are 15 CM
LAYOUT CIRCUIT
CONDITIONS
S1 L1 L2
ON DIM DIM
OFF OFF OFF
PROCEDURE
SITTTR Kalamassery
8. SCHEMATIC LAYOUT IN DOMESTIC WIRING SYSTEM
Energy meter - used to measure electic power in the circuit. Its unit is KWh - Kilo
What hour.
ELCB - Earth Leakage Circuit Breakers. This devi ce sences the current flowa to earth and
automatically isolate the supply to the load.
Main Switch - It is a device used to isolate the supply manually when required.
Cut - out - Used to isolate supply without operating the main switch.
Distribution Board (DB) - It is used to isolate each sub circuit from the supply by
removing the fuse carrier or miniature Circuit Breakers.
Sub Circuit - If the load in a circuit is less than 800W or number of points in a path is less
than 10, it is known as a sub circuit. It is controlled by DB.
SITTTR Kalamassery
109
Activity:
• Observe and identify the types of earthing used in your school building and your home.
• Find out the reason for larger size of earth pin compared to other two pins used in 3 pin plug.
• Enquire about the systems used for protection from the lightning.
Questions:
1. What is the use of earthing?
2. What are the two systems of earthing?
3. What are the factors affecting the earth resistance?
4. Explain the procedure of pipe earthing.
5. What are the objectives of earthing?
6. Draw the energy meter connection in block diagram as per new convention.
7. What are the things to be done for earthing domestic appliances.
8. Write the permissible values of earth resistance in different situations.
9. To wire up a meter board.
*******
SITTTR Kalamassery

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GOVERNMENT OF KERALA

DEPARTMENT OF TECHNICAL EDUCATION

NATIONAL VOCATIONAL EDUCATION QUALIFICATIONS

LEARNING RESOURCE FOR

STATE INSTITUTE OF TECHNICAL TEACHERS

Phone & Fax: 0484 2542355

The learning resource on Electrical Equipment Maintenance is a comprehensive

The material is prepared in a language and style easily digestible to the

Smt. A.S.Chandrakanta, Principal, Govt.Women’s Polytechnic College, Thrissur

Shri. P. P. Baby, Asst.Director, Supervisory Development Centre, Kalamassery

Shri.T. V. Francis, Project Officer, SITTTR, Kalamassery

Shri. Biju Peter, Project Officer, SITTTR, Kalamassery

V A Shamsudeen, Deputy Director, SITTTR, Kalamassery

Technical Expert Committee

Shri. Vijai.T.V, Lecturer in EEE, GPTC, Palakkad.

Shri. Manohari.C.B, Lecturer in ECE, WPTC, Thrissur.

Shri. Aneef.A, Demonstrator in EEE, GPTC, Palakkad.

Mr. Augustine Kuriyakose, Lecturer in EE, GPTC Palai

Design & Layout : Smt. Shincy T P, Women’s Polytechnic College, Thrissur

i Provide a general introduction to the subject from the appropriate beginning

Suggestions for improvement of the structure and presentation of the learning

Chairman, Learning Resource Committee for THS

CHAPTER 2. BASICS OF ELECTRICITY 33

CHAPTER 3. JOINTS AND WIRING

1. To lift a heavy motor to a table using any approcpriate method.

CHAPTER 4 EARTHING AND ENERGY METER

1. To introduce the concept of safety.

Note to the teacher

1. Display videos related to fire and safety.

How can we ensure safety?

1.2 Classification of safety

1.3 Safety at work

Most of the accidents are caused by:

 not using safety guards.

 using faulty or improper tools and equipments.

 negligent or overconfident actions.

 inadequate light & ventilation.

Let us consider some of the safety precautions to be taken while at work:

1.3.1 Lifting & Handling of loads manually

Wearing leather gloves will prevent accidents while handling

Crushing of feet or hands:

PRECAUTIONS: Feet and hands should be

• Make sure that the route is clear for the movement.

• Ensure proper holdings for the load.

• Position in a comfortable way with legs

• Then bend the knee such that the load is held

• Hold the load in a grip and keep the back

• Gradually apply force to straighten the legs

1.3.2 Moving Heavy loads

Careless movement of crane

They are used to pull heavy load along the ground

Using Moving Platforms:

They are used to move heavy equipments.

• Position the platform using jack or other lifting method,

• When the load is fully balanced on platform, allow the Fig 8

1.3.3 Safety in using Tools & Equipments

• work with tools & equipments in a firm physical