Unit 9 Booklet-electrical-revised

9 Month Certification Program
Electrical
Unit 9
Install Lighting Systems

ELECTRICAL
Module 9.1
USE ELECTRICAL
TEST EQUIPMENT
TABLE OF CONTENTS
Unit 9: Install Lighting Systems
Module 9.1
Use Electrical Test Equipment
TRAINEE HANDBOOK
Information Sheets 1
Task Aid
INFORMATION SHEET
Enabling Objectives
Terminal Objective
9.1.1
Unaided, the trainee will correctly Unaided, the trainee will
classifymultimeter types. correctly use electrical test
equipment and follow
9.1.2 faultfinding techniques to
Unaided, the trainee will correctly state the locate faults on lighting
equipment condition and connection methods wiring systems.
tomeasure voltage, current and resistance safely.
9.1.3
Unaided, the trainee will correctly identify the
partsand state the uses of electrical test
equipment.
INTRODUCTION
So far, you have learned what electricity is and what

produces it. In this module, you will learn how to
measure it safely. You will learn how to use electrical
test equipment to measure voltage current and
resistance.
In part I, you will learn to identify and classify

different types of multimeters. In part II, learning
how to connect and use both analog and digital
multimeters is your task. Part III covers the parts
and uses of other electrical test equipment, mainly
the Meg-Ohm meter and the Clamp-on ammeter.
Finally, you will use test equipment to locate faults
on a lighting wiring system.
1
INFORMATION SHEET
PART I OBJECTIVE 9.1.1
Classify Multimeter Types
As an electrical craftsman, you will often need to

measure voltage, current, and resistance. You need to
do this to test and troubleshoot circuits and their
components. To do most of these tasks, you will use
a multimeter.
A multimeter is a piece of equipment with several

functions. Depending on the model type, you can
use it to measure resistance and a wide range of dc
and ac voltages and currents.
There are two types of multimeters, analog and

There are only two multimeter
types, but many different digital. These names come from how the meter
manufacturers make different displays the measurement. In the analog meter, you
models.
read off the measurement from a pointer or needle
moving across a background scale. In the digital
meter, your readings are displayed as numbers on a
digital display.
ANALOG SCALE DIGITAL SCALE
Figure 1
Analog and Digital Meter Displays
2
INFORMATION SHEET
There are many different multimeter models. Each

one may have a different layout and measure
different ranges. However, they all operate in a
similar manner.
To classify a multimeter you must first determine its

type. Remember that an analog meter has a needle
on a scale. A digital meter shows numbers directly.
Once you know the type, you can classify a

multimeter by what it measures. For example, some
multimeters measure voltage and resistance. Some
measure voltage and current, and some voltage,
current and resistance. If a meter measures more than
During your career, you will find
just one item, it is a multimeter. that there are different
combinations of multimeter. To
be a multimeter, it must
You now know the multimeter type and what it measure more than one thing.
measures. However, you must also know the range (A voltmeter measures only
voltage. An ammeter measures
of the units it measures. only current. An ohmmeter
measures only resistance).
Does the meter measure what you need? For
example, to find faults on your car, it must measure
around 12vdc. However, if you wanted to fault find
on your air conditioner, it would need to measure
more than 220vac.
The meter’s measurement range is important. You

must know the range and always measure less than
the maximum figure. Depending on the type of
meter you use, the meters accuracy can also change
with the range. For example, because of its scale, an
analog multimeter with a range of 0–1000V would
be inaccurate and very hard to read at voltages
around 10V.
3
INFORMATION SHEET
Question: How do you find out a multimeter’s

range?
Answer: There are two ways to check the range of a

Use of manufacturers’ manuals
is covered in depth in the next multimeter. Most meters have the figures printed by
module. the range selector switch or switches. However, to be
certain of what your multimeter can measure (and
the ranges it measures), read its manual.
Your instructor will now pass out some multimeter

manuals. Use these to complete exercise A.
SUMMARY
You have now learned to classify multimeters by:
❏ type: digital or analog

❏ functions: voltage, current, and/or resistance
❏ measurement range: 0–10 mA, 0–50v etc.
You have also learned that to get specific

information, you must look in the manufacturer’s
manual.
In the next part, you will learn how to use

Meter models are
different. Make sure you multimeters. The meters you use in this module
read the manufacturers’ measure voltage, current, and resistance. That means
manual. This lists information
on the meter’s functions, ranges that they contain an ammeter, a voltmeter and an
and limits. ohmmeter.
4
INFORMATION SHEET
EXERCISE A
Directions: Your instructor will hand out multimeter
manufacturer’s manuals. He will then ask you some
questions about the meter ranges and capabilities. Use the
manuals to find the answers to the questions.
INFORMATION SHEET
PART II OBJECTIVE 9.1.2
State the Equipment Condition and Connection

Methods to Measure Voltage, Current, and
Resistance Safely
To use any multimeter safely, there are some basic

rules you must follow. These cover the equipment
condition and meter connection methods. These
basic rules apply for all types of multimeter, analog
and digital. You must learn to use a multimeter
correctly if you wish to be successful in your career
as an electrical craftsman.
EQUIPMENT CONDITION
❏ To measure resistance the meter supplies its
own power. Therefore, the equipment or wiring
you want to check must be dead or de-
energized. This means no power connected or
switched to where you will install the meter
test leads.
❏ To measure voltage, you want to measure the
Make sure your hands
never come into contact potential difference between two points. To do
with live equipment. this, there must be power available. Therefore,
equipment must be live or energized when you
take measurements.
❏ To measure current, you want to measure the
electrons flowing through the circuit. Therefore,
the equipment must be live or energized when
you take your readings.
6
INFORMATION SHEET
CONNECTION METHODS
❏ To measure resistance (with power off ), make
sure that you are measuring only one circuit or
current path. For example, to measure the value
of one resistor, you isolate that resistor from the
rest of the circuit. If you measure across more
than one circuit, your measurements will be
meaningless (see figure 2). Also, make sure you
know what range you have selected. If you do
not know the range, you can not get a correct
reading.
Figure 2
Measuring Resistance
❏ Measuring voltage: You must start by making

sure that the voltage you expect is well inside
meter limits. If it is, select the highest range
before connecting the meter. When you connect
the test leads, connect them in parallel to the
circuit you want to measure. Connect the
meter to the circuit (see figure 3). If needed
(depending on the meter model), work down MEASURE VOLTAGE
IN PARALLEL
the range scales until you have the most
accurate reading. Figure 3
Measuring Voltage
7
INFORMATION SHEET
Note: As you measure voltage on live equipment,

when possible, attach the test leads one at a time.
By doing this, you reduce the chance of receiving a
dangerous electric shock across your chest.
❏ Measuring current: You want to measure the

electrons flowing through the circuit. To do
this you must connect the meter in series with
the circuit. This means that the meter becomes
part of the circuit and the electron flow is
directly through the meter (see figure 4).
FLUKE 87 TRUE ARMS MULTIMETER

FLUKE 87 TRUE ARMS MULTIMETER
AUTO 100 ms RECORD MAX MN AVG H AC DC AUTO 100 ms RECORD MAX MN AVG H AC DC
u m VA u m VA
nFS% nFS%
M k Hz M k Hz
0 1 2 3 4 5 6 7 8 9 0 0 1 2 3 4 5 6 7 8 9 0
4000 4000
mV mV
MIN MAX RANGE HOLD H MIN MAX RANGE HOLD H
REL Hz REL Hz
PEAK MIN MAX PEAK MIN MAX
mV mV
mA mA
V A V A
V uA V uA
OFF OFF
A mA u A COM V A mA u A COM V
400mA MAX 400mA MAX

FUSED FUSED
10A MAX 1000V MAX 10A MAX 1000V MAX
FUSED FUSED
! !
Figure 4
Measuring Current
Selecting Meter Functions
Measuring current, you

As you now know, each multimeter model is slightly
must turn power off different. For this reason, you must check its manual
before opening the
circuit to make the meter
to find out what functions are available and how
connection. You must also turn you select them.
power off before removing the
meter leads.
8
INFORMATION SHEET
Connecting Test Leads
Again, you must know what test lead connections

your multimeter has (depend on the model it is).
Therefore, you must check the relevant
manufacturer’s manual to find out these details.
SUMMARY
In this part, you have learned how to classify

multimeters. You found out how you must connect
multimeters, the condition that equipment must be
in, (live or de-energized) and how to set and read
the meter scales. You have also practiced using two
different types of multimeter, digital and analog. You
can now make basic voltage, current, and resistance
measurement safely.
You also learned one other important fact while

completing this part. That is, how important
manufacturers manuals are.
9
INFORMATION SHEET
EXERCISE B
Part 1
Directions: Write the correct answers in the spaces
provided.
1. In what condition must equipment be to

measure resistance?
2. How do you connect a multimeter for

measuring current?
3. Where do you check the range scale of a

multimeter?
4. How do you connect a multimeter to measure

voltage?
5. When measuring resistance on de-energized

equipment, what must you check?
6. What must you do before connecting a

multimeter to measure circuit current?
10
INFORMATION SHEET
Part 2
Directions: Write down the meter safety rules your
instructor tells you. It is in your interest to remember these
guidelines.
11
INFORMATION SHEET
PART III OBJECTIVE 9.1.3
Identify the Parts and State the Uses of Electrical

Test Equipment
ELECTRICAL TEST EQUIPMENT

This part introduces you to a very important part of
an electrician's job: how to identify and find faults
on wiring systems. To do this, you will learn how to
use two new types of electrical test equipment:
❏ the meg-ohm meter

❏ the clamp-on ammeter
You will learn how to use these meters, along with

other test equipment, to find faults on wiring
systems. To be a successful electrician, it is
important that you learn the correct procedures to
follow when you find a fault. Once learned, these
skills will help you throughout your career.
MEG-OHM METERS
Earlier, you learned that the multimeter is a very
important piece of test equipment. However,
sometimes it can not tell you everything you need
to know. Therefore, to be able to troubleshoot, you
Commonly, people shorten the need some different test equipment so you can
name meg-ohm meter to just
“megger”.
measure and test different things. One important
piece of test equipment electricians regularly use is
the meg-ohm meter.
Dual = two or twin.

A meg-ohm meter is a dual-purpose test meter. As
Dual purpose = two uses.
an electrical craftsman, you will use this meter to
measure:
❏ insulation resistance
❏ continuity
12
INFORMATION SHEET
Insulation Resistance
This test checks that the circuit or equipment
insulation is in good condition. Insulation resistance A million ohms is a meg-ohm,
written as MΩ.
is large, so it is measured in millions of ohms.
Continuity
This test checks that there is a continuous circuit
Continuity is measured in ohms.
through the conductor or coil.
Meg-Ohm Meter Parts

To understand how to use the meg-ohm meter, you
Note: Different manufacturers
must be able to identify the meter type, its parts, make different models of meg-
and its controls. ohm meter. You must check the
meter’s manufacturer’s manual
for specific information.
As with multimeters, there are many different types
of meg-ohm meter. However, most types have the
same features as the example shown in figure 5.
Those features are as follows:
❏ a clutch controlled, hand operated generator

❏ one meter with two scales, Meg-ohm and Ohm
❏ terminals to connect test leads
❏ a selector switch
❏ a carrying handle
TEST TERMINALS
SELECTOR
SWITCH
SCALE
CARRYING
HANDLE
HAND CRANK
POINTER
TO OPERATE
GENERATOR
Figure 5
Meg-Ohm Meter
13
INFORMATION SHEET
Compare these features with the meg-ohm models

shown in figure 6 and the model in your workshop.
Figure 6
Different Types of Meg-Ohm Meter
14
INFORMATION SHEET
Hand Crank
On the model shown in figure 5, turning the crank

Note: As some work areas
operates the generator. The generator produces the contain flammable gases,
output voltage needed for the meter’s test. It is fitted “intrinsically safe” meters are
used. To reduce the danger of
with a clutch that slips when the crank is turned fast sparking, these produce voltage
enough to produce the correct voltage. from a button press circuit, not
a generator.
Selector Switch
The selector switch lets you select the meters output

voltage and meg-ohm range.
Scales
Like the multimeters you used earlier, the meg-ohm

meter display may be analog or digital. Reading
from the digital display is simple, as long as you
remember what range you selected. However, reading
from the analog scales requires more thought.
Commonly, analog type meg-ohm meters have two

200 0
scales: 0
0.255
100
50
OHMS
1
0.2
0.5
100
0.05
20 2 50 500
0.1 10 5
0.2 200
❏
20
an ohm scale: for measuring continuity 0.5
1 2 5
10
100
0.5 50
❏
1
a meg-ohm scale: for measuring insulation 2
5 10
20
MEGOHMS
resistance
Figure 7
Typical Meg-Ohm Meter Scales
Reading from the Scale
On all meg-ohm meters, when measuring continuity,

you set the selector switch to the OHMS position. 200 0
0.2
You can then take reading from the ohms scale. 100
OHMS 0.5
50 1
Figure 8 shows a typical analog ohms scale. 20 10 5
2
The scale shows or indicates resistance values from

zero to 200 ohms (0–200Ω). When reading from Figure 8
Ohm Scale
this scale, if the pointer is between the scale
15
INFORMATION SHEET
divisions, you must estimate the resistance value. For

200
0.2
0
example, Figure 9 shows the pointer between the 1
100
50
OHMS
1
0.5
and 2 ohm divisions. Therefore, the estimated
2
20 10 5 resistance reading is approximately 1.25 ohms
(11/4Ω).
Figure 9
Estimate Ohm Scale To measure insulation resistance, you must set the
selector switch as needed for the task, and then take
readings from the relevant meg-ohm scale.
Figure 10 shows a meg-ohm scale for a simple two-

range (500 V/MΩ, 1000 V/MΩ) meter. In this
example, the 500 V/MΩ range uses the top of the
scale. The 1000 V/MΩ range uses the bottom of the
scale.
Infinity = limitless. Shown as

the symbol ∞
0
0.255 ON THE 500 V / 100 M
100
0.05 RANGE
50 500
0.1 USE THIS SCALE
0.2 200
20
100
0.5
1 10
2 5
0.5 50
1
2 10
20 ON THE 1000 V / 500 M
5
RANGE USE THIS SCALE
Figure 10
Meg-Ohm Scale
The meg-ohm scale indicates resistance values from zero ohms to
infinity. Like the ohms scale, if the pointer is between divisions you
must estimate the resistance value.
16
INFORMATION SHEET
Identifying Range Selections
Meg-ohm meters have two or more meg-ohm range

You must check the
selections. The reason for these, with their different manufacturer’s manual for
voltage ranges, is to provide different test voltages. details of any meter you use.
Commonly, 120V/220V light fixture and receptacle

branch circuits are wired with cables that have a
600-volt insulation rating. This means the cable is
designed to withstand a voltage of up to 600 V.
Therefore, if using a two-range meter (500 V/MΩ,
1000 V/MΩ), you would use the 500 V/MΩ
selection. If you were checking circuits wired with a
higher rated cable, for example, a 480-volt motor
with a cable rated at 1000V, you would need to test
its insulation at the 1000 V/MΩ selection.
Your instructor will now demonstrate the range

selections and scales used on the meg-ohm meters
in your workshop.
Minimum Values of Insulation Resistance
Normally, you would not make a decision on what

Where kilovolts (kV) is the
is an acceptable minimum value of insulation rated machine terminal-to-
resistance. One meg-ohm (1MΩ) is widely used as a terminal voltage, you can find
the recommended minimum
lower limit for insulation resistance on industrial insulation resistance (Rm) for
electrical equipment rated up to 1000 volts. For rotating machines by:
equipment rated above 1000 volts, as a general Rm = kV + 1
indication, a minimum of one meg-ohm per one

thousand volts is used.
17
INFORMATION SHEET
Measuring Ground Continuity and

Insulation Resistance
Question: Why is it important to have good ground

The importance of having
low ground continuity continuity?
resistance cannot be
overemphasized. A life may
depend upon it... YOURS! Answer: Because any leakage current must have a
low resistance path to ground. This ensures it opens
the circuit fuse or operates the circuit breaker. This
precaution prevents a dangerous rise in voltage on
the metal work of an installation.
Testing Ground Continuity
In figure 11, the ground wire is looped from one

item to another.
TB 1
CB 1
L N SW 1 L1
120 V
CB 1 1 3
3 2
L1
SW 1
1 3 3 2 2
A B
L2 4 2
1 4
SW 2
1 4 4 2 SW 2
L2
SCHEMATIC DIAGRAM WIRING DIAGRAM
Figure 11
A Simple Schematic and Wiring Diagram
18
INFORMATION SHEET
In part “B” there are four (4) ground wire loops:
❏ TB1 to SW1
❏ SW1 to SW2
❏ SW2 to L2
❏ L2 to L1
Excluding the terminal board connection (TB1),

there are four grounding terminations, the last
connected to L1. Therefore, to test for ground wire
continuity, connect the meter across the grounding
termination at L1 and the ground termination at
TB1. (See figure 12).
TB 1
CB 1
SW 1 L1
1 3
3 2
4 2
1 4
SW 2
L2
Figure 12
Ground Continuity Test
19
INFORMATION SHEET
In addition to checking grounding wire continuity,

this test also verifies (confirms) the effectiveness of
the terminations.
It is not always practical to connect the meter test

leads directly across the ends of the grounding wire.
The distance between the grounding wire ends may
be too large. To overcome this problem, you can
make use of the existing wiring.
In figure 13, the neutral wire runs in a continuous

length between TB1 and lighting fixture L1.
JUMPER
WIRE
TB 1
CB 1
SW 1 L1
1 3 3
2
4 2
1 4
SW 2
L2
Figure 13
Ground Continuity Test Using a Jumper Wire
20
INFORMATION SHEET
The jumper wire is connected across the neutral and

grounding terminals of TB1. The jumper wire is
either a short length of wire directly connected
across the terminals, or a short length of wire
terminated with alligator clips.
The meg-ohm meter (on the OHMS scale) is

connected across the neutral terminal of L1 (#2) and
the grounding terminal, both connections being
made at the light fixture L1.
The meg-ohm meter readings for ground wire

Any reading above zero means
continuity should be zero. there is a fault.
Insulation Resistance Testing
A poorly insulated wire is a hazard. It provides the

To test insulation, the meg-ohm
risk of electric shock and/or fire. When you perform meter voltage applied to a 110/
an insulation test, check that for a given test voltage 220 V branch circuit would be
500 volts.
there is no current flow through the insulation.
There are two types of insulation resistance test:
❏ insulation resistance to ground

❏ insulation resistance across conductors
To Ground
As the name implies, this checks that the insulation

resistance between the live wire (called line) and
ground is of a high enough value to prevent a
leakage current to ground.
21
INFORMATION SHEET
JUMPER
WIRE
TB 1
CB 1
SW 1 L1
L N
120 V 1 3
CB 1 3 2
L1
SW 1
1 3 3 2 2
L2 4 2
1 4
SW 2
1 4 4 2 SW 2
L2
Figure 14
Insulation Resistance to Ground
Refer to figure 14. The meg-ohm meter is
connected to the linked live and neutral wires and
the grounding terminal at TB1. For the test, the
circuit conditions are:
❏ circuit de-energized (no power)

These conditions are for the
wiring diagram shown. In ❏ circuit breaker closed (made)
practice, you may need to test
at the breaker terminal with the
❏ neutral wire disconnected from TB1
circuit breaker open.
❏ lamp L1 and L2 removed
❏ switches SW1 and SW2 closed
The neutral wire has been disconnected. This

prevents the possibility of a circuit to the ground
through the neutral terminal (which may have a
deliberate ground reference). The switches SW1 and
SW2 are closed to check all the live (line)
conductors for ground insulation. If the switches
were open, there would be isolated sections of the
circuit not checked.
22
INFORMATION SHEET
Across Conductors
You must check the insulation resistance value
between conductors, especially conductors of
opposite polarity. That is, line (live) to neutral, or
line to line.
Figure 15 shows you what conditions you need to

test the insulation resistance across the line (live)
wiring and the neutral return. These conditions are:
❏ circuit breaker CB1 closed

❏ switches SW1 and SW2 closed
❏ lamps L1 and L2 removed from fixtures
TB 1
CB 1
SW 1 L1
L N
120 V 1 3
CB 1 3 2
L1
SW 1
1 3 3 2 2
L2 4 2
1 4
SW 2
1 4 4 2 SW 2
L2
Figure 15
Insulation Resistance Test
With the meter connected at the line and neutral

terminals of TB1, you can measure the insulation
resistance of the line to neutral conductors.
23
INFORMATION SHEET
For specific information you CLAMP-ON AMMETERS

must refer to the meter’s
manual. Measuring current is not easy because you must
break the circuit to connect an ammeter. However,
Always make sure that you test there is a meter that lets you measure AC current
only one conductor at a time. If
easily: the clamp-on ammeter.
you test two conductors
together, your readings will be
false.
A clamp-on ammeter measures AC current flow in a
single conductor. By using this meter, you can do
this without having to make, or break, any
connections in the circuit under test. You simply
clamp the meter over the conductor.
Parts
As with all equipment, different manufacturers

produce different meter types and models (see figure
16). Figure 17 shows the parts you will find on a
typical clamp-on ammeter.
CLAMP
POINTER
LOCK BUTTON
LATCH SCALE
SELECTOR
SCALE
ZERO ADJUST
SCREW
POINTER
OHMMETER
ZERO ADJUST
KNOB
OHMMETER
VOLTAGE TEST RECEPTACLE
RECEPTACLES
Figure 17
Figure 16 Parts of the Clamp-On Ammeter
Different Clamp-On Models
24
INFORMATION SHEET
Clamp
A clamp encloses (fits around) the conductor under
test.
Latch
When pressed, the latch opens the clamp so you can
connect the meter to the conductor.
Scale
Depending on the meter type and model, the scale
can be an analog scale or a digital indicator.
Depending on the meter type and configuration, it
can be used to read currents, voltages, and resistance.
Scale Selector
Depending on meter type and model, you use the
scale selector buttons or rotating selector to set the
range scale and meter function.
Pointer
On an analog meter, the pointer shows the value of
the scale reading.
Pointer Lock Button

Sometimes it is hard to read the meter when it is
connected. To overcome this, some meters have a
button that lets you lock the pointer or reading. You
can then read off the measurement when you
remove the meter from the circuit.
Zero Adjust Screw

Fitted on analog meters, the zero adjust screw lets
Initial means first.
you set the pointer to zero before taking initial
readings from the circuit.
25
INFORMATION SHEET
Voltage Test Receptacles
When fitted, the voltage test receptacles terminals let

you use the meter to test for voltage.
Ohmmeter Receptacle
When fitted, the ohmmeter receptacle terminal lets

you use the meter to test resistance.
Ohmmeter Zero
On analog meters, while being used as an

ohmmeter, the ohmmeter zero function lets you set
the pointer for ohms zero.
Your instructor will now demonstrate how to use the

type of clamp–on ammeter you have in your
workshop.
SUMMARY
In this part, you have studied how to use a meg-

ohm meter to test insulation and continuity. You
have also learned how to use another piece of
electricians test equipment, the clamp-on ammeter.
It is important that you remember what you have

learned. You will need the skills and knowledge you
gained in this module throughout your training and
to be successful in your career as an electrical
craftsman.
26
INFORMATION SHEET
EXERCISE C
Part 1
Directions: Your instructor will show you different readings
on a meg-ohm meter scale. You must identify what figure
the meter is reading.
Part 2
Directions: Answer the following questions in the spaces
provided.
1. What are the two things that a meg-ohm meter

measures?
2. What does a continuity test check?
3. If you wanted to check the insulation on a

piece of equipment rated at 900V, what meg-
ohm meter selection would you use?
4. Why must you check for ground continuity?
27
INFORMATION SHEET
EXERCISE D
Part 1
Directions: Your instructor will give you a clamp-on
ammeter and ask you to measure the current passing
through cables. Your instructor will tell you how he wants
you to record your findings.
Part 2
Directions: Write the answers to the following questions in
the spaces provided.
1. Where would you find details of a specific

clamp-on ammeter?
2. Why is the clamp-on ammeter sometimes easier

to use than a standard multimeter?
3. What type of current does a clamp-on ammeter

measure?
28
ELECTRICAL
Module 9.2
REPLACE CONDUIT
AND FITTINGS
TABLE OF CONTENTS
Module 9.2
Replace Conduit and Fittings
TRAINEE HANDBOOK
INFORMATION SHEET
State the Need for Different Types of Conduit
An industrial plant has many hazardous areas. For

this reason, cables and wires must be protected. A
spark from a damaged cable or bad connection
could easily cause a gas explosion or fire. Therefore,
all plant wiring is routed through conduit. Conduit
is a pipe or tube that protects electric wires and
cables.
CONDUIT TYPES
Conduit is used in many locations, for example:
❏ industrial plants and shops

❏ commercial buildings
❏ residential areas and houses
Different cable types and loads need different levels

of protection. There are different conduit types for
different applications. The types of conduit used are:
EMT ❏ Electrical Metallic Tubing (EMT) – thin-walled

metal tube used in low voltage applications for
commercial buildings.
FLEXIBLE METAL CONDUIT

❏ Flexible metal – a thin metal strip shaped into
a spiral tube. It is flexible and used where
access is difficult. It is commonly used to
protect wiring going to motors or other
equipment that vibrates during use.
LIQUID TIGHT FLEXIBLE
METAL CONDUIT
Figure 1
Common Conduit Types
2
INFORMATION SHEET
EXERCISE A
provided.
1. Why do some types of conduit have a plastic

or PVC coating?
2. Can a raceway be used in a hazardous area?
3. What types of conduit could be used safely in a

hazardous area?
4
INFORMATION SHEET
90 ANGLE CONNECTOR STRAIGHT CONNECTOR 45 ANGLE CONNECTOR
Figure 5
Seal Conduit Connectors
RIGID STEEL FITTINGS
Rigid conduit is explosion-proof and gives the best

Note: Preparation, connection
mechanical protection. It is used in all hazardous methods, and installation of
rigid steel conduit and fittings
areas. Therefore, this is the main type of conduit you
will be covered further in parts
use when working as a Saudi Aramco electrician. III and IV.
To ensure maximum protection, this conduit uses a

number of special threaded fittings. This means that
the ends of rigid conduit must be cut, reamed, and COUPLING
threaded. (This will be covered in part III.)
To connect two threaded ends together you use a

threaded coupling (see figure 6).
Sometimes, you will be unable to use a threaded

coupling. For example:
Figure 6
Rigid Conduit Threaded Coupling
❏ conduit installation extensions where tube
sections can not be physically turned
❏ emergency repair work
❏ in hard to access areas, near corners, walls,
ceilings, etc.
7
INFORMATION SHEET
In cases like these, you must use a conduit union

UNF TYPE
assembly. (See figure 7).
UNASSEMBLED
TWO FEMALE HUBS
ASSEMBLED
UNY TYPE
ONE FEMALE HUB
ONE MALE HUB
Figure 7
Rigid Conduit Union
Sometimes, you must connect a conduit tube of one

1.2" CONDUIT
diameter to a tube of a different diameter. Threaded
3/4" TO 1/2" reducers (see figure 8) allow you to do this.
(19mm) (13mm)
3/4"-THREADED
REDUCER BOX
BUSHING
LOCKNUT
Figure 8
Threaded Reducer
8
INFORMATION SHEET
PVC COATED RIGID STEEL
Almost all rigid conduit fixtures have a PVC coated

equivalent. These ensure that the conduit provides
the maximum protection from the environment.
Because of this, when you use PVC coated conduit,
you must take extra care not to damage the PVC
coating. If the PVC coating becomes cracked or
damaged, it will not provide the environmental
protection needed.
SUMMARY
In this part, you have learned that there are many

different conduit fixtures available. Each type of
conduit has its own specialized fixtures. You also
learned that rules for installation are provided in the
NEC.
When installing conduit, you must use only the type

specified in your maintenance documentation.
Remember, although rigid conduit tubing is
explosion proof, some of the fixtures are not.
Therefore, you must check to ensure you use only
explosion-proof fixtures in hazardous areas.
In the next part, you will learn how, and practice

producing, rigid conduit installations.
15
INFORMATION SHEET
EXERCISE B
Directions: Your instructor will show you some examples
of different conduit fittings. Identify the conduit type and
applications of use. Your instructor will tell you if he
requires you to provide written answers or oral answers as
part of a class discussion.
16
INFORMATION SHEET
EXERCISE D
Directions: Your instructor will hand out some rigid steel
conduit. Follow the procedure outlines in HO 9.2-1 andunder PCV coated rigid steel conduit
your instructor’s guidance, use the ratchet bender tomake a may be used in this exercise.
90° bend and a three-point saddle bend from rigidconduit.
35
INFORMATION SHEET
EXERCISE E
Directions: Your instructor will give you some circuits and
show you areas in which conduit for them must be
installed. Plan and calculate the installation requirements,
(wiring and fixtures) and the conduit lengths and bends
needed.
43
44
TASK AID
REMOVE AND REPLACE A PIECE OF

CONDUIT
1. Receive work permit, prepare your tools and

material. Then perform the required lockout
and hold tag procedures.
2. Measure the overall length of conduit A.

Refer to Installation Diagram in
figure 55.
3. Remove all old conductors from the switch
box, panel board and lamp.
4. Loosen the unions and remove old conduit A.

Remove the seal and discard old conduit.
5. Form the replacement conduit piece. (With 90°

bend and offset).
6. Cut, thread, and ream the replacement conduit

at both ends.
7. Fix seal to conduit as per diagram.

Refer to Installation Diagram in
figure 55.
8. Fix unions and install replacement conduit.
9. Cut cables to required length, leaving 6" at

each end for connections.
10. Pull cable through conduit.
11. Prepare and apply sealing compound to seal.

Have your instructor inspect it, then remove
sealing compound.
12. Perform housekeeping of your work area.
47
TASK AID
HID LIGHT FIXTURE

IL1
HID LAMP BASE

GND
GREEN
WHITE
GREEN
WHITE
BLACK
GREEN
WHITE
BLACK
UNION
"A"
SEAL
UNION
GREEN
BLACK
WHITE
GREEN
BLACK
RED
GND
LIVE NEUTRAL
TERMINAL TERMINAL
CIRCUIT CIRCUIT
BREAKER BREAKER
GND
CIRCUIT CIRCUIT
BREAKER BREAKER
CIRCUIT CIRCUIT
BREAKER BREAKER
CIRCUIT CIRCUIT
BREAKER BREAKER
SW BOX EXPLOSION-PROOF
CIRCUIT BREAKERS LIGHT SWITCH (SW1)
EXPLOSION-PROOF
PANELBOARD SINGLE-POLE SWITCH
PANELBOARD
Figure 55
48
TABLE OF CONTENTS
Module 9.3
Replace Fuses, Disconnect Switches, and Circuit Breakers
TRAINEE HANDBOOK
INFORMATION SHEET
Enabling Objectives
Terminal Objective
9.3.1
Given tools, equipment, and
Unaided, the trainee will correctly state the use material, the trainee will
offuses, disconnect switches, and circuit breakers. remove and replace fuses,
9.3.2 disconnect switches, and
Unaided, the trainee will correctly state the circuit breakers, then
safetyand testing guidelines for removal and check the circuit for
replacementof fuses, disconnect switches,and correct operation.
circuit breakers.
INTRODUCTION
In this module, you will study about some

important electrical safety devices: fuses, disconnect
switches, and circuit breakers.
In part I, you will learn what parts make up these

devices, what they look like, and how they operate.
In part II, you will learn and practice removal and
replacement of fuses and molded case circuit
breakers from electrical circuits or equipment. The
skills you learn in this module will be of direct use
to you when you begin work in the field.
1
INFORMATION SHEET
State the Use of Fuses, Disconnect Switches, and

Circuit Breakers
Fuses, disconnect switches, and circuit breakers are

all safety devices. When they operate, they cause an
open circuit to prevent current flow. Therefore, their
operation isolates the circuit or equipment.
Fuses
On some old equipment, you

There are many different fuse shapes. However, as
may see different types of fuses. an electrical craftsman you will mainly use the
For example plug type. Always
check the vendors manual or
cartridge fuse. These come in two basic types:
equipment specifications.
❏ ferrule
❏ knife blade
Ferrule
FERRULE TYPE
These fuses have metal caps or contacts on each
end. These caps allow the fuse to fit securely and
make a good electrical contact with the fuse holder
BLADE clip. In Saudi Aramco, ferrule fuses are commonly
CONTACT ENDS
used for current applications up to 60A.
KNIFE BLADE TYPE
BLADE
Figure 1
Ferrule and Knife Blade Cartridge Fuses
2
INFORMATION SHEET
Knife Blade
These fuses have metal strips, called knife blades,

extending from each end of the fuse. Commonly,
the knife blades slot into the fuse clip. Some knife
blade fuses have blades that have holes or spade
connections. The design you use depends on the
fuse holder. In Saudi Aramco, knife blade fuses are
used for high current applications above 60A.
Figure 2
Fuse Operation Knife Blade Hole and Spade Ends
Inside the fuse, there is some form of metal fuse END CAP
ARC QUENCHING END CAP
link or fuse wire. This provides protection for the FUSE LINK POWDER
circuit or equipment being energized. The structure

of the internal fuse link determines how a fuse
operates (its application). CONTACT POINT
FUSE CASING
CONTACT POINT
Figure 3
The link, sometimes called an element, is designed Basic Fuse Link
to melt or blow when too much current flows
through it. When the link melts, the fuse becomes
To stop the melting link from
an open circuit, preventing any further current flow. burning, the fuse is filled with
arc quenching powder. This
powder stops the arc burning.
The maximum current that can flow before the fuse
link blows is the current rating. For example, a 5A
fuse will pass current up to 5A. If more current
flows, the link melts, and the fuse becomes open
circuit.
3
INFORMATION SHEET
BEFORE OPERATION Fuse Link Types

FUSE CASING
GOOD LINK One-Time Links
Both ferrule and knife blade fuses use one-time fuse

links. When the internal link melts, the fuse
cartridge must be discarded and replaced with a new
METAL END CAPS
CONTACT POINTS
fuse. The fuse can be used only one time.
FUSE CASING
BLOWN LINK One problem with a simple fuse link is that it may
not melt at exactly the rated current. In addition to
this, it may not melt evenly and may blow too
quickly or too slowly. To overcome these problems
METAL END CAPS there are different types of fuse linkages.
CONTACT POINTS
AFTER OPERATION
THROUGH OVERCURRENT Dual Element
Figure 4 Fuses with dual element links are used to protect
One-Time Fuse Operation
circuits with motor loads. These types of fuse are
sometimes called slow blow. A dual element link has
TIME DELAY ONE-TIME
ELEMENT ELEMENT two elements. One of these elements is made of a
thermal, time delay alloy. If the circuit has a small
current overload, the time delay dissipates the heat
for a short time. If the overload continues past a
Figure 5 short time, it melts the alloy.
Cutaway of One Type of Dual
Element Fuse
If the protected circuit has a short, a very high
When you dissipate heat, you current will flow. (Remember for a constant EMF, if
spread it out over a larger area.
This makes a large area warm, resistance reduces, current increases). This high
instead of a small area hot. current causes the other element to blow as though
it was a one-time fuse link. Just like the one-time
fuse, when it has operated (become open circuit),
dual element fuses must be removed and replaced.
Figure 6
Spring Type Dual Element Fuse
4
INFORMATION SHEET
Renewable Link Fuses
It is sometimes cheaper to replace a link rather than FUSE CASING END CAP
RENEWABLE
the whole fuse (including the case and caps/knife LINK
SCREWS
OFF
blades). Renewable link fuses are used in many

applications such as motors, power feeder, and
lighting circuits. Because of physical size, the use of ONE-TIME RENEWABLE LINK FUSE
END CAPS
renewable link fuses is usually restricted to higher TIME DELAY
LINK PLATES
FUSE SCREW OFF
KNIFE BLADE CASING
current ratings.
Renewable links are available for both one-time and

TIME-DELAY RENEWABLE LINK FUSE
time delay fuses. For safety, voltage and current
levels are stamped directly onto the fuse link. Figure 7
Renewable Fuse Links
CURRENT LIMITING FUSES
Just as some circuits use slow-blow fuses, others,

QUARTZ SAND KNIFE BLADE
usually high voltage circuits, need fuses that blow
immediately their current rating is reached. In other
words, fuses that ‘limit’ current flow to an exact
MULTIPLE SILVER LINKS
level. CONTACT POINT CONTACT POINT
Figure 8
Because of their quick operation, current limiting Current Limiting Fuse
fuses are found in high voltage feeders, transformers,
and motor circuits.
To ensure that they can operate quickly (and at an

exact level) current limiting fuses use a number of
thin links rather than one or two thicker links.
These thin links melt quicker and, as there is no
single large burning arc, safer. This is because the
thin elements burn at a lower temperature, reducing
the risk of the fuse case becoming too hot and
exploding.
5
INFORMATION SHEET
Fuse Identification
Fuse cases are labeled to identify the fuse type,
Do not rely only on the
information on the fuse you voltage, and current rating. The label data includes
remove. Someone else may all the relevant details about the fuse. This lets you
have fitted the wrong fuse rating
or type! Always check the select the correct replacement.
maintenance documentation
(vendor manual etc.) to find the
fuse you need.
FUSE END CAP

FUSE LABEL
AMPERAGE
RATING
CLASS OR VOLTAGE RATING

SYMBOL
FUSE LINK TYPE

AND FUNCTION
Figure 9
Fuse Labeling
DISCONNECT SWITCHES
Disconnect switch: In a power system, a switch used
for closing, opening, or changing the connections in
a circuit or system or for purposes of isolation.
Note: It has no interrupting rating and is intended to be

operated only after the circuit has been opened by some
other means, such as by a circuit breaker or variable
transformer.
There are two basic types:
❏ non-fused: Refer to figure 10A. This identifies

the parts of a non-fused disconnect switch
6
INFORMATION SHEET
❏ fused: Refer to figure 10B. This identifies the

parts of a fused disconnect switch used in a
non-hazardous area. This type of disconnect
switch is used in many Aramco facilities where
there is no danger of gas
Table 1 lists common parts of disconnect switches.
Name Description
Handle to manually throw the switch blade

to isolate the load from power
Moving Switch open and close the circuit path

Blades between the fuses and the power
source
Fuse Holder Clips provide a socket base for securing

the fuses
Line Connection top connection point for the line

Lugs conductors
Load Connection lower connecting point for the load

Lugs conductors
Mechanical prevents the door being opened

Interlock while the switch is energized. It also
prevents closing the switch while
the door is open
Door prevents accidental contact with live

parts
7
INFORMATION SHEET
ARC CHUTE
LINE LUGS
SWITCH
BLADE
MECHANICAL
INTERLOCK
DOOR
LOAD
CONNECTION
LUGS
SWITCH HANDLE
A
LINE CONNECTION
ARC CHUTE MECHANICAL INTERLOCK
LUGS
SWITCH
BLADE
FUSES
SPRING
FUSE HOLDER
CLIPS
DOOR
SWITCH
HANDLE
LOAD CONNECTION LUGS
B TERMINALS
Figure 10
A. Non-Fused Disconnect Switch
B. Fused Disconnect Switch
8
INFORMATION SHEET
CIRCUIT BREAKERS
As you learned earlier, a circuit breaker acts as an

automatic switch. If an over-current occurs, the CB
trips and opens the circuit. You can also use a CB
to manually switch power ON and OFF.
If a CB trips, unlike a fuse it does not have to be

replaced. You reset it by hand. If the cause of the
over-current has been corrected, the CB will remain
closed. If not, it will trip again. To reset the circuit
breaker, move the handle from the tripped position
to the reset position, then back to the ON position.
Note: In some cases the handle is moved to the OFF

position, then back to the ON position.
Molded case CB’s have three methods of operation:
❏ thermal trip
❏ magnetic trip
❏ combined thermal and magnetic trip
Thermal Trip
Thermal circuit breakers operate in response to the

heat generated by over-current.
9
INFORMATION SHEET
A bimetallic strip is two different Refer to figure 11. When the contacts close current
metals joined in one strip. When flows through the heater. As the current increases,
heated, the metals expand at
different rates, bending the the heater gets hotter. On over-current, the heat is
strip. enough to bend the bimetallic strip. The spring then
forces the contacts apart, causing an open circuit.
LOAD LOAD OVERLOAD
CONTACTS OPEN
CONTACT BAR
CONTACTS CLOSED
SPRING BIMETALLIC
STRIP SPRING
BIMETALLIC
STRIP
FLEXIBLE HEATER FLEXIBLE HEATER

CONDUCTOR CONDUCTOR
POWER SOURCE POWER SOURCE
ON CONDITION TRIPPED CONDITION
Figure 11
Thermal Trip
LOAD
Magnetic Trip
ON CONDITION
Magnetic circuit breakers operate on the principle of

CONTACTS CLOSED electromagnetic induction.
ARMATURE LATCHED
SPRING
SERIES COIL
FLEXIBLE
Refer to figure 12. When the contacts close, current
CONDUCTOR
IRON CORE
flows through the coil. If the current increases, the
POWER SOURCE
coil’s magnetic field increases. On over-current, the
LOAD OVERLOAD
magnetic field becomes strong enough to attract the
TRIPPED CONDITION
armature. The spring then forces the contacts apart,
CONTACTS OPEN
opening the circuit.
ARMATURE
UNLATCHED
SPRING
SERIES COIL
FLEXIBLE
CONDUCTOR
POWER SOURCE Figure 12

Magnetic Trip
10
INFORMATION SHEET
Combined Thermal-Magnetic Trip
These CB’s have both a thermal trip unit and a

magnetic trip unit. The thermal trip will operate on
small over-currents e.g., circuit overload. The
magnetic trip will operate on high over-currents e.g.,
short circuit.
GROUNDING PRINCIPLES
The purpose of grounding is safety. Grounding

At ground potential, all exposed
reduces electric shock and fire danger. Grounding parts of the installation are at
ensures the safety of non-current carrying metal the same potential, zero volts.
parts of an installation (equipment frames etc), by

making them equal to ground potential.
Grounding also provides a convenient path to

ground for any fault current. This helps the
operation of circuit fuses or circuit breakers.
Figure 13 shows the danger of a circuit with no

grounding conductor connected to the exposed
metal work of equipment.
CIRCUIT BREAKER
TRANSFORMER LIVE
LIVE FAULT
MOTOR TO MOTOR FRAME
WINDING
120V 120V IN MOTOR
NEUTRAL
120V
0V
LIVE
GROUND
120V
Figure 13
Circuit with No Grounding Conductor
11
INFORMATION SHEET
In figure 13, a motor winding fault to the frame has

caused a high potential difference between the frame
and the ground. In this condition, anyone touching
the frame could get an electric shock. The circuit
breaker would remain closed. This would be a very
unsafe situation.
This problem can be overcome by grounding all

exposed metal parts of the installation.
CIRCUIT BREAKER
TRANSFORMER LIVE
LIVE FAULT
TO FRAME
MOTOR
NEUTRAL
(GROUNDED CONDUCTOR)
GROUND
FAULT
CURRENT
GROUNDING
CONDUCTOR
LIVE
GROUND
SYSTEM GROUND
SERVICE GROUND
Figure 14
Path for Ground Fault Current
In the system shown in figure 14, the motor frame

is grounded. Because of this, the fault current will
flow through this low resistance path more readily
than through the high resistance of a human body.
The resistance of the fault will be very low, let’s say

0.01 ohm. The applied voltage is 120 volts. The
current can be found using Ohm’s Law.
12
INFORMATION SHEET
It can be seen from the example that a ground fault

would cause a very high current. This would operate
the circuit isolation devices (fuse/CB) very quickly.
Without ground connections, fault current would

not flow. The circuit protection may not operate
and anyone touching the frame could receive an
electric shock.
To keep the resistance as low as possible, grounding While providing a low

connections must be tight and clean. A poor resistance path, the grounding
wire must also be of the correct
connection has a high resistance. This would ampacity needed by that
decrease the fault current, possibly preventing circuit equipment.
protection devices from operating.
Figure 15 shows a circuit with a high resistance

grounding connection.
TRANSFORMER 30 V CIRCUIT BREAKER

LIVE
LIVE FAULT
TO FRAME
HIGH RESISTANCE
MOTOR GROUNDING CONNECTION
NEUTRAL
(GROUNDED CONDUCTOR)
GROUND
SYSTEM GROUND SYSTEM GROUND
Figure 15
Circuit With High Resistance Grounding Connection
13
INFORMATION SHEET
Let’s say the resistance of the fault is 0.01 ohm and

the resistance of the grounding connection is 4.99
ohm. By Ohm’s law:
V 120 120
I= = = = 24 A
R 0.01 + 4.99 5
A fault current of 24A will not trip the 30A CB.

Remember, even a small
electric shock can kill! Therefore, if you touched the motor frame, your
body would complete a circuit to ground. You
would receive an electric shock. There is also the
danger of the increased current generating enough
heat to start a fire.
So far you have studied the basic operation of CB’s

and the principles of grounding. You will now
increase your knowledge by learning more about
molded case circuit breakers (MCCBs) and ground
fault circuit interrupters (GFCI).
A ground fault on an electrical tool or appliance can

give you an electrical shock. It can do this because
the fault current may be too low to blow the fuse or
trip the circuit breaker. Unfortunately, if you supply
a path to ground by contact with metal or the
ground, the current can still be high enough to kill
you.
To stop the chance of this, the combination circuit

breaker and GFCI is used. These respond to low
milliampere ground faults. These devices operate on
a very low ground fault current (approximately 5
milliamperes (mA). Remember, a current as low as
25 mA flowing through your body can be fatal! This
is a very small current, only 1/40th of one ampere.
14
INFORMATION SHEET
Figure 16A shows a single-pole combination circuit

breaker and ground fault interrupter (GFCI). As you
can see from figure 16B, the GFCI may also be
constructed as a double (two)-pole or triple (three)-
pole type.
HANDLE
A
NEUTRAL CONDUCTOR
TO LOAD
TEST BUTTON LINE CONDUCTOR

TO LOAD
SINGLE-POLE
TO PANELBOARD
NEUTRAL
GROUND FAULT
TEST BUTTON
B
DOUBLE-POLE
TRIPLE-POLE
PANEL NEUTRAL CONNECTION
Figure 16
A. Single-Pole Combination CB and GFCI
B. Double-Pole and Triple-Pole Combination CB and GFCI
15
INFORMATION SHEET
The GFCI operates on overload, over-current, and

ground faults of very small currents. You have already
learned how a basic circuit breaker operates. Now
you will learn the component parts and operation of
the GCFI circuit breaker. (See figure 17).
Note: In figure 17, as there is

no ground fault current flowing, COIL
the two currents are the same
and in balance. The circuit will DIFFERENTIAL TRANSFORMER
not cause the interrupting AC POWER 5A CURRENT FLOW LOAD

device to open. 5A
INTERRUPTING ZERO DIFFERENCE CURRENT

DEVICE
SENSING AND
TEST CIRCUITS
GFCI
Figure 17
The GFCI Circuit
Differential Transformer
This compares two currents. It provides an output

signal only if a difference occurs between the
currents.
Sensing and Test Circuits
These contain an electronic amplifier. It receives any

signal from the transformer and, if needed, sends an
output signal to the interrupting device.
Interrupting Device
If a signal is received from the sensing circuits, a

solenoid or coil operates this device.
The following steps state the operation of the GFCI

circuit when a ground fault occurs. Follow the
circuit operation in figure 18.
16
INFORMATION SHEET
COIL
DIFFERENTIAL TRANSFORMER
AC POWER 5A LOAD
4A
INTERRUPTING 1 A DIFFERENCE CURRENT

DEVICE
1 A FAULT
CURRENT
SENSING AND
TEST CIRCUITS
GFCI
Figure 18
Circuit With A Ground Fault
When a ground fault occurs, the current flow

between two conductors becomes unbalanced. This
unbalance causes a change in the differential
transformer’s magnetic field.
Through electromagnetic induction, this charge

induces a voltage in the transformers secondary
winding. This voltage causes a current to flow in the
sensing circuit.
The current flow in the sensing circuit activates the

coil of the interrupting device. This opens the load
circuit. The circuit is now safe because you have
isolated the ground fault.
SUMMARY
In this part, you have learned about fuses,
disconnect switches, and circuit breakers. You have
learned why they are used and how they operate.
The maintenance of isolating and protective devices
is important to the operation and reliability of
electrical distribution systems. Therefore, it is an
important part of your job as an electrical craftsman.
In the next part of this module, you will learn to

test, remove, and replace these safety devices.
17
INFORMATION SHEET
EXERCISE A
provided.
1. What is the purpose of fuses, CB’s and

disconnect switches?
2. What type of fuse does Saudi Aramco use on

currents above 60A?
3. What is a fuse or CB’s current rating?
4. What is the advantage of a dual element fuse?
5. What type of fuses blow immediately when

they reach their current rating?
6. What are the two main types of disconnect

switch used in Saudi Aramco plants?
7. Why must equipment be grounded?
18
INFORMATION SHEET
State the Safety and Testing Guidelines for

Removal and Replacement of Fuses, Disconnect
Switches, and Circuit Breakers
So far, you have learned why isolation devices are You must always
used and how they operate. As an electrician, you think SAFETY when
working on electrical
must be able to test and maintain these devices. equipment. Before
That means that you must know how to remove testing, removing, or replacing
any electrical part, ensure you
them from equipment, check and test them and have the required authority,
replace them as needed. paperwork and have followed all
required lockout procedures. If
in any doubt, ASK!
FUSES
As you know, when faultfinding you check a

diagram or schematic to see if you can locate the
faulted area. From these checks, you may determine
that a blown fuse could be causing the problem.
This is quite common.
After you have used the diagrams/vendor manuals to

identify the faulted disconnect switch (and possibly
determined which actual fuse) you must test the
switch and fuse to confirm that they have a fault.
Testing a fuse for open circuit is simple. Depending

upon the fuse type, and the equipment into which
it’s fitted, you can test it with power ON or OFF.
19
INFORMATION SHEET
Continuity Test
❏ Check that power is switched OFF.
❏ Remove the fuse from its holder or clip before
performing the test.
Note: Always use an insulated fuse remover, or

puller for this task.
❏ Use a multimeter and perform a continuity test

across the fuse.
POWER SOURCE
L1 L2 L3
DISCONNECT SWITCH OPEN
NON CONDUCTIVE
FUSE PULLERS
F F F
U U U
S S S
E E E
T1 T2 T3
TO LOAD
Figure 19
Fuse Puller
Removing the fuse from circuit prevents any possibility of measuring
separate circuit paths.
Voltage Test
You use the multimeter to measure voltage between

phases, between each phase and ground, and across
each fuse (see figure 20). Remember, when
measuring across the fuse, if the fuse is blown (open
circuit) there will be a difference in potential across
it. If the fuse is good, there will be no potential
difference across it.
Your instructor will now demonstrate how to safely,

test fuses with power OFF, and with power ON.
Figure 20
Power On Fuse Voltage Checks
20
INFORMATION SHEET
DISCONNECT SWITCHES
As these contain mechanical parts and mechanical

connections, they need maintenance. After you have
prepared for the task and performed any needed
safety procedures, check the security of the fittings:
door, connector lugs, fuse holder clips, etc. Check
the lug terminations are secure and correct. Look
out for signs of burning or over-heating. These often
show that current rating has been exceeded.
Again, while working on simple disconnect switches,

it is easy to forget basic safety. Therefore, before
performing maintenance or replacing a disconnect
switch, make sure you are aware of all safety factors.
Use the manuals to find any information you are
not sure of.
Your instructor will now demonstrate how to safely

inspect and perform insulation/resistance test on a
disconnect switch.
CB AND GFCI
When you check these breakers, perform your first

check with power on. Test for voltage at the line
and load terminals. (See figure 21).
LOAD CONDUCTORS
CIRCUIT BREAKER
LOAD TERMINAL
VOLTMETER
LOAD CONDUCTORS NEUTRAL BUS

TERMINAL
Figure 21
Testing an MCCB For Voltage
21
INFORMATION SHEET
With power on, if you find voltage at the line side,

and no voltage at the load terminal (with the
breaker switched to ON), you simply replace the
breaker. You also replace the breaker if, with the
load disconnected, it trips or you cannot reset it.
The combination CB and GFCI has a special test

button. When operated, this simulates a ground
fault in the internal circuit of the GFCI. Therefore,
if the unit is working, the CB trips.
You reset the GFCI by placing the handle in the

OFF position and then in the ON position. (See
figure 22).
LOAD TERMINALS
PUSH TO TEST
CIRCUIT BREAKER BEFORE TEST

IN ON POSITION
BREAKER IN
TRIP POSITION TEST ACTION
BREAKER RETURNED
TO ON POSITION
BREAKER IS PLACED
IN OFF POSITION AFTER TEST
TO RESET
Figure 22
Testing the GFCI
22
INFORMATION SHEET
Inspection of CB and GFCI’s is important because

it helps you:
❏ determine necessary maintenance INSPECT THE CASE AROUND

THE BUS CONNECTION TERMINAL
❏ determine if replacement is necessary
❏ solve some maintenance and operating
problems
❏ prevent costly unscheduled equipment
shutdown
You should inspect the casing and terminals of all

types of molded case circuit breakers. This includes
single-pole, double-pole, and triple-pole types.
INSPECT THE CASE AROUND
THE LOAD TERMINALS (S)
When inspecting the case, look for: Figure 23

Inspecting the Case
❏ Discoloration or burn spots showing high
temperatures, possibly from excessive load or
poor terminal connection.
❏ Cracking, again a sign of over-temperature -
may indicate high load currents, loose or
improper terminal connections.
23
INFORMATION SHEET
When inspecting the terminals, look for a tight fit

on the bus connection. Check bus bar bolt
connections.
You must also check for a tight connection within

the circuit breaker. Terminals should not be loose.
Check for discoloration, blue or black coloring of
the terminal, or any pitting of the contacts. These
are all signs of over-temperature and/or corrosion.
Terminals should be a bright metallic color.
DISCOLORATION
OF TERMINALS
THIS END IS OPPOSITE

OF LOAD END
INSPECT BUS CONNECTION

INSPECT LOAD TERMINALS
TERMINALS HERE
HERE
Figure 24
Inspecting the Terminals
Your instructor will now demonstrate how to safely

inspect a disconnect switch.
24
INFORMATION SHEET
SUMMARY
In this module, you have studied the use, operation,

and maintenance of basic isolation devices. You have
also learned that you must think of, and follow
safety precautions even when performing simple
tasks.
Your instructor has demonstrated the checks you

need to perform for testing and inspecting the
isolation devices in your workshop. However, you
must remember that different manufacturers’
equipment may need different tools, maintenance
and safety precautions. Therefore, always check the
vendor’s manual for information.
25
INFORMATION SHEET
EXERCISE B
provided.
1. What tool must you use to remove fuses from

their clips?
2. Where do you find information about the

isolation device you are working on?
3. When you are testing a CB, what is your first

check?
4. What should happen when you operate a

GFCI test button?
5. Why must you inspect isolation devices for

discoloration’s?
26
ELECTRICAL
Module 9.4
INSTALL LIGHT
FIXTURES AND
FITTINGS
TABLE OF CONTENTS
Module 9.4
Replace Light Fixtures and Fittings
TRAINEE HANDBOOK
INFORMATION SHEET
Enabling Objectives
Terminal Objective
9.4.1
Unaided, the trainee will
Unaided, the trainee will correctly classify types
correctly replace light
offlorescent light fixtures.
fixtures and fittings.
9.4.2
Unaided, the trainee will correctly classify types
ofhigh intensity, gas discharge light fixtures.
9.4.3
Unaided, the trainee will correctly state the
connection guidelines for receptacles and
fittings.
9.4.4
Unaided, the trainee will correctly state the use
ofcontactor’s and photocells in lighting systems.
9.4.5
Unaided, the trainee will correctly state the
safetyrequirements relating to the maintenance
of lightfixtures.
INTRODUCTION
The most common type of light fixture is the

incandescent lamp. These are the screw or bayonet
fitting light bulbs used in most homes. However,
incandescent lighting is not practical for large areas.
To produce light of a high enough intensity, safely,
without causing excessive heat or maintenance,
different lighting systems are used.
In this module, you will learn about fluorescent and

high intensity, gas discharge light fixtures. These
1
INFORMATION SHEET
both produce the high levels of illumination needed

in large rooms, workshops and around the plants.
You will also learn how different types of switches
and switching circuits can be used to control
lighting. You will then learn some practical circuit
connections and how and why contactors and
photocells are used in lighting circuits. Finally, you
will learn some important safety information you
will need to remember when maintaining lighting
systems.
When you have completed the information sections

you will perform a task aid. This will involve
replacing a light fitting, fitting a switch in a
receptacle, and connecting a lighting circuit. You will
perform these tasks on the conduit installation you
worked on in the last module.
2
INFORMATION SHEET
Classify Types of Florescent Light Fixtures
Florescent light fixtures are PREHEAT STARTER TYPE

very common in both LAMP HOLDER
LAMP HOLDER
BODY BALLAST
STARTER SOCKET
commercial and residential
areas. You will see them in
many sizes and shapes
LID
depending upon their STARTER
application. However,
DOUBLE PINS DOUBLE PINS
FLUORESCENT LAMP
fluorescent fixtures are
grouped into three types based BODY
RAPID STARTER TYPE
on the method they use to
start the lamp.
BALLAST
❏ preheat start type

LAMP HOLDER LAMP HOLDER
❏ rapid start type LID
❏ instant start type

DOUBLE PINS DOUBLE PINS
FLUORESCENT LAMP
Before you learn the
differences between types, you INSTANT STARTER TYPE
LAMP HOLDER
BODY
must first learn what parts LAMP HOLDER BALLAST
SPRING-LOADED
SOCKET
make up a typical florescent

fitting. (See figure 1).
LID
The body is the main fixture

housing. It may be mounted SINGLE PIN
FLUORESCENT LAMP
SINGLE PIN
in a ceiling or suspended by
supports. Figure 1
Fluorescent Lighting Fixtures
The lid covers and protects the wiring and major

parts.
3
INFORMATION SHEET
Holders for the double pin The lamp tube holder holds the fluorescent lamp
tubes are generally designed (tubes) in position and provides connection points to
so that the tube must be
inserted and rotated to make the circuit.
contact.
Fluorescent lamps commonly called tubes, provide

light. A tube is made of glass with a cathode at each
end. It is filled with an inert (non flammable or
When mixed with air, reactive) gas such as argon or mercury vapor. It
the fluorescent produces invisible ultraviolet light when conducting
phosphor powder
that covers the inside electricity. To make the light visible, the inside of
of the tube is POISONOUS. If the glass tube is coated with a fluorescent material
the glass breaks avoid contact
with skin or eyes. (phosphor). Phosphor produces visible light when
ultraviolet energy passes through it.
Each tube is marked with information so you can

select the tube you need. This information includes:
❏ wattage
❏ color: cool white (CW), daylight (D), warm
white (WW)
❏ starting method
The ballast is a combination of an autotransformer

and one or two capacitors.
A fluorescent lamp is an arc discharge device. When

illuminated it has a very small resistance. Therefore,
the current will rapidly increase after the start cycle
has begun. If this current were not controlled, it
would destroy the lamp. Therefore, the ballast’s
autotransformer controls the current flow. Basically, it:
❏ supplies high voltage for starting the lamp

❏ limits the current flowing through the lamp
4
INFORMATION SHEET
Ballasts may have one capacitor to reduce radio Stroboscopic effect will be
interference and another to provide phase shifting to covered later.
reduce stroboscopic effect for two-tube operation.
The starter helps the ballast produce the initial high Note: Newer fluorescent
voltage for starting the lamp. (See note). lighting fixtures, called rapid
start and instant start, produce
enough initial voltage without
OPERATING PRINCIPLES a starter. Their lamps light up
almost immediately.
As you learned, there are three different types of
fluorescent lighting fixtures. The general operating
principles of these is very similar. It is the method of
starting the lamp that differs.
Preheat Start Type
Refer to figure 2. When the circuit is energized, a

small current flows through the ballast to cathode A STARTER
STARTER
BASE
and through the starter to cathode B. This current
causes the starter to heat up, making the starter
contacts close. The contacts allow the start current
to flow, heating lamp cathode B. The argon gas in
the lamp heats up and conducts more current than
STARTER
the starter. With the reduction in current through
the starter, its bimetallic contact supports cool, and
the contacts open. This makes the magnetic field of FLUORESCENT LAMP
the ballast collapse. The reactance (ac resistance) of

the ballast causes it to produce a high voltage pulse
SWITCH
that strikes the arc across the fluorescent lamp. BALLAST AC SOURCE
LINE
When an arc is struck, the ballast internal resistance

Figure 2
limits excessive current flowing through it. (The Preheat Start Circuit
lamp remains illuminated).
Note: The starter operates for a brief period when the

circuit is first energized. The ballast only provides the high The preheat start lamp is
voltage on starting (momentary), when it strikes the arc becoming obsolete and is not
across the fluorescent lamp. widely used on newer plant
installations.
5
INFORMATION SHEET
Rapid Start Type
The rapid start type is the most common type of

fluorescent fitting. Each cathode has two connection
points connected to a two-wire circuit. (See figure 3).
CAUSES LAMP 2
QUICK-HEAT CATHODE LEAD-IN BALLAST TO LEAD LAMP 1
BALLAST
(LOW RESISTANCE) WIRES
SOURCE SOURCE
BALLAST
LAMP LAMP 1 LAMP 2
Single-lamp, rapid-start circuit Circuit for two rapid-start lamps in series.

120 VOLTS
Figure 3
Rapid Start Circuit
The rapid start ballast is made to deliver a small

voltage (approximately 4V) to continuously heat the
cathodes. No starter is needed. The hot cathodes
heat the gas inside the lamp. When the circuit is
energized, the lamp will produce light quickly with
very little flicker.
Instant Start Type

LAMP 2
Though operating similarly to the rapid start lamp,

this lamp does not preheat the cathodes. The
LAMP 1
cathodes are shorted at each end with one, single
connection to the circuit. Therefore, the ballast of
the instant start produces a higher voltage than the
rapid start ballast.
CAUSES LAMP 1
TO LEAD LAMP 2
BALLAST
When energized, enough voltage is applied across the
cathodes to create an instantaneous arc. This allows
120 V
60 Hz the lamp to give off light immediately. (See figure 4).
Figure 4
Instant Start Circuit
6
INFORMATION SHEET
APPLICATIONS
Rapid start and instant start lamps are used to

provide the lighting in many applications. For
example:
❏ equipment areas (motors, pumps, etc.) Flickering florescent

lamps near rotating
❏ plant work areas (machine shop, electrical shop) machinery can be dangerous
because of stroboscopic
❏ office space, classrooms effect.
❏ control rooms and test labs
SUMMARY
In this part, you have studied fluorescent lamp

fixtures. You learned that even though there are
many different makes and models, electrically they Even though there
are (electrically)
are divided into three groups: preheat, rapid, and three types of fluorescent
instant start. fixtures, there are many
different models. The standard
model fitting (i.e. those in the
You learned that a preheat start needs a starter to classroom) are not explosion
proof. Therefore, special
heat up before operation. A rapid start provides a explosion proof models must
small continuous voltage to heat the cathodes, and be used in hazardous areas.
an instant start operates similarly, but uses a higher
voltage.
Your instructor will now demonstrate the procedure

for removal and replacement of fluorescent fixtures/
tubes. After this, complete exercise A.
7
INFORMATION SHEET
EXERCISE A
Part 1
provided.
1. What gives off visible light when exposed to

ultraviolet energy?
2. What type of fluorescent fixture uses a

bimetallic strip in its starting circuit?
3. What are the two functions of a fluorescent

fixture’s ballast?
4. What word describes the dangerous effect that

fluorescent fixtures have on rotating equipment?
5. What type of fluorescent fixture can be used in

a hazardous area?
Part 2
Directions: Perform basic maintenance tasks on
fluorescent lighting fixtures/tubes as directed by your
instructor.
8
INFORMATION SHEET
Classify Types of High Intensity, Gas Discharge

Light Fixtures
As you learned in the last part, fluorescent light When handling HID
fixtures are in common use. However, in the plant bulbs, never touch
the glass with bare
environment, lighting and safety requirements mean hands. Finger print
that another type of lighting is often used: high oils and moisture on the
surface of the bulb glass cause
intensity gas discharge lighting (HID). the glass to distort and break
when the lamp is on and bulb
glass temperature rises.
FIXTURE ASSEMBLY
As with all electrical equipment, to understand how

HID lighting works, you must first know the fixture MOUNTING FITTING
parts and their functions. COVER ASSEMBLY
The mounting fitting and cover assembly are shown BALLAST HOUSING
in figure 5. The mounting attaches the fixture to NAMEPLATE
conduit. The cover is connected to the mounting HID LAMP

(MERCURY VAPOR
and contains the supply and lamp conductors. OR SODIUM VAPOR)
GLOBE ASSEMBLY BASE

GLOBE
GUARD
Figure 5
HID Lighting Fixture
9
INFORMATION SHEET
200-400 WATT HOUSING

The ballast housing is attached to the cover assembly
this protects the ballast, the capacitor, and the lamp
CAPACITOR socket. (See figure 6).
The ballast assembly at the center of the fixture

BALLAST
holds the ballast and capacitor. The capacitor
LAMP SOCKET increases the lamp’s power factor and aids in
maintaining constant wattage. Ballasts like this are
needed for both mercury vapor and sodium vapor
50-175 WATT HOUSING
lamps.
LAMP SOCKET
CAPACITOR
BALLAST
Figure 6
Ballast Housing and Assembly
10
INFORMATION SHEET
The globe assembly adds protection for the bulb

ELECTRIC LIGHTING
glass and an aid in redirecting the light evenly. FIXTURE FOR
HAZARDOUS
LOCATIONS
CLASS 1 DIVISIONS 2
SUITABLE FOR
The guard protects the globe against physical WET LOCATIONS
damage.
The fixture nameplate provides ordering information

for replacement parts. It is also important for
identifying the conditions and applications where the
CAT
fixture can be used. (See figure 7). No. VMVS2A400/120RM
M
DIV2 O MB
D
MAX AMPS AMPS
VOLTS START OPER
120 1.20 4.20
INPUT MIN
WATTS 463 PFS
90 H2 60
LAMP TYPE
E18/E37/BT37
INPUT MAX
WATTS S51 WATTS 400
40 T1 85
55 T1 90
FOR SUPPLY CONNECTIONS.

USE WIRES SUITABLE FOR AT LEAST.
FOR CORRECT INSTALLATION USED AND
MAINTENANCE, SEE INSTRUCTIONS PACKED
WITH FIXTURE
Figure 7
Nameplate
11
INFORMATION SHEET
The HID lamp (bulb) produces light. There are two

LAMP BASE types of bulbs commonly used in Saudi Aramco
plants.
❏ mercury vapor
❏ sodium vapor
STARTING
ELECTRODE
OPERATING
Mercury Vapor
ELECTRODES
The starting electrode strikes an arc and warms the

ARC TUBE
mercury gas in the tube. Once struck, the operating
electrodes maintain the electric arc. The mercury gas
OUTER BULB allows current to flow between the electrodes
producing light. The outer bulb protects the lamp
parts from corrosion. It also filters out dangerous
Figure 8 (ultraviolet) light waves. Nitrogen fills the space
Mercury Vapor Bulb
between the inner and outer bulbs. This gas filled
space protects the arc tube from large changes in
temperature that would shatter the hot arc tube.
This is called the nitrogen blanket.
Sodium Vapor
A sodium vapor buld is constructed similar to a

SODIUM
mercury vapor lamp. However, the high-pressure
VAPOR
sodium lamp (HPS) does not need a starting
ARC TUBE
electrode. Instead, it uses a special high-voltage pulse
OUTER
ELECTRODES circuit within the ballast. When the arc is struck,
BULB
current flows through the sodium vapor gas,
producing light. The arc tube is again protected by
the outer tube.
BASE
Figure 9
Sodium Vapor Bulb
12
INFORMATION SHEET
OPERATION BALLAST
CASING CAPACITOR
The HID lighting fixture operates on the same basic

arcing principle as the fluorescent lamp.
LAMP
Mercury Vapor
The typical mercury vapor lamp circuit consists of a LINE
6
constant wattage auto-transformer ballast and a 7 MAIN
ELECTRODE
capacitor. ELECTRIC ARC
THROUGH MERCURY
VAPOR
5 4
STARTING
When energized, the ballast delivers high voltage to ARC TUBE
ELECTRODE
the lamp’s starting and main electrodes. A starting 6

MAIN
3
STARTING
resistor controls current flow and an arc is struck at ELECTRODE
RESISTOR
the starting electrode. The mercury vapor in the

tube begins to heat up, warming the main electrodes 1
BASE
and giving off a dim glow. When heated sufficiently, LINE

BALLAST
2
an arc strikes through the vapor between the main VOLTAGE TO LAMP
electrodes. The arc tube becomes a bright blue-green Figure 10

glow of light. Mercury Vapor Lamp Circuit
If the bulb is illuminated, and the outer bulb Mercury vapor lamp start times
accidentally breaks, NEVER look into the bare average from 3 to 7 minutes.
mercury arc tube. Mercury vapor produces Starting time is shorter when
ultraviolet light. This causes eye damage and the ambient temperature is
loss of vision. Turn the power off and replace the lamp. high.
Sodium Vapor
In addition to a ballast and capacitor, high-pressure

sodium (HPS) lamp circuits have a starting circuit
(sometimes called an igniter circuit).
13
INFORMATION SHEET
When switched on, the ballast energizes the igniter

3 circuit. The igniter circuit delivers a high frequency,
ELECTRODE high pulse voltage to the electrodes. When an arc is
4 struck, the tube glows dimly. The sodium vapor in
ARC TUBE
the tube heats up, increasing in brightness until it
6
reaches full illumination. Then, the ballast limits the
CURRENT FLOWS current through the arc tube reducing its voltage
THROUGH SODIUM VAPOR
output.
3
ELECTRODE
If the power is interrupted, or the voltage drops
below that needed to maintain an arc, all HID
lamps lose their arc and go out. The lamp will not
restrike immediately because the vapor pressure is
5 high and too hot to be ionized at the normal
BASE
1
starting voltage. The restrike time for a sodium
BALLAST vapor lamp is less than 1 minute, the warm up time
LINE
is two to three minutes. A much higher voltage
2 would be needed to start the lamp immediately. This
2
STARTING
STARTING
VOLTAGE
is not practical, therefore, the gas in the lamp must
CIRCUIT
TO LAMP
be allowed to cool down.
Figure 11
Sodium Vapor Lamp Circuit APPLICATION
HID lamps operate on voltages

HID lamps are used to provide lighting in:
of 120V, 208V, 277V, and
480V. ❏ refinery areas and walkways around equipment
❏ around switch gear and motor control center
❏ around valves and control equipment for piping
❏ street lighting and indoor work areas
Your instructor will now demonstrate the correct

handling procedure for removal and replacement of
HID bulbs. After this, complete exercise B.
14
INFORMATION SHEET
SUMMARY
In this part, you have learned the parts and

operations of HID fittings. You know that you must
never touch the bulb with bare hands. Mercury
vapor and sodium vapor bulbs require time to fully
illuminate, and after operating, they must cool down
before re-lighting.
15
INFORMATION SHEET
EXERCISE B
Part 1
provided.
1. What is the effect of touching an HID bulb

with your bare hands?
2. Why do HID ballast circuits use a capacitor?
3. What type of HID lamp has a starting

electrode?
4. What does an igniter circuit provide?
Part 2
Directions: Perform basic maintenance tasks on HID
lighting fixtures/bulbs as directed by your instructor.
16
INFORMATION SHEET
PART III OBJECTIVE 9.4.3
State the Connection Guidelines for Receptacles

and Fittings
Switches are control devices used to open and close This part contains
a circuit. They are connected between the source of general switching
and receptacle
power and the load. In this part, you will learn how information. You
single-pole, three-way, and four-way switches are must remember that in
hazardous areas all switches
used to control lights from different points. You will and receptacles must be an
also learn the basics of connecting up receptacles and explosion proof type.
panelboards.
In an AC circuit, switches are
always connected on the line
SWITCHING conductor.
One important part of a lighting circuit is the

control switching. Different types of switching allow Switches must be connected so
that when the switch is down,
a light circuit to be controlled from switches in a the circuit is deenergized.
number of different locations. (See figure 12).
LIGHT
LIGHT
ONE POINT CONTROL TWO POINT CONTROL THREE POINT CONTROL
Figure 12
One, Two, and Three Point Control Switching
17
INFORMATION SHEET
Single-Pole Switch
Signal-pole switch symbol on

This is the simplest type of switch. It controls a load
a drawing $. from one point (see figure 12). It has two terminals.
When switched in the ON (closed) position, current
flows through the switch. When in the OFF (open)
SWITCH position, current flow stops. The single-pole switch is
TERMINALS
connected to only one conductor.
NEUTRAL WHITE
BLACK BLACK
SINGLE-POLE
SWITCH LIGHT
LINE
AC SOURCE
Figure 13
Single-Pole Switch
18
INFORMATION SHEET
Three-Way Switch
The three-way switch is used to control a light from Three-Way switch symbol on
two different points (see figure 12). It has three a drawing $3.
terminals. One, called the common terminal (c) is
located on one side of the switch. It is dark in color
and appears to be tarnished. The other two
terminals are brightly colored brass. These terminals 3
provide connection for conductors to another three-
way switch to make two-point control possible. (See
figure 14).
The three-way switch is designed so that current will

flow in either position. For this reason the handle of
the switch is not marked ON or OFF. SWITCH TERMINALS
Circuit Connection
CURRENT FLOW
INPUT c c OUTPUT
Refer to figure 15. In this circuit, the line conductor
is connected to the common terminal of switch one.
Two conductors (called strappers or travelers) are Figure 14
connected between the two brightly colored brass Three-Way Switch
terminals on the opposite side of switch one and

switch two. The line conductor of the light is
connected to the common terminal of switch two,
with the neutral conductor connected directly to the
light. Operating either switch will turn the light on
or off. You would use a multimeter to verify switch
terminals.
19
INFORMATION SHEET
WHITE
LIGHT
3 3
NEUTRAL CONDUCTOR
BLACK
1 LINE CONDUCTOR TO LOAD 2

STRAPPERS
RED
C
BLACK C
BLACK
WHITE SOURCE LINE CONDUCTOR
Figure 15
Three-Way Switch Connection
Four-Way Switch
Four-way switch symbol on a The four-way switch is used to control a load (light
drawing $4. fixture) from a third point. (See figure 12). It has
four terminals, all of the same color.
The four-way switch is connected between two,

three-way switches as shown in figure 16. (The
strappers remain the same color.)
4
WHITE LIGHT
LINE CONDUCTOR TO LOAD
3-WAY FOUR WAY

c RED RED
BLACK BLACK c
3-WAY
FOUR WAY SWITCH
LINE(BLACK) STRAPPERS
TO SUPPLY
N P
Figure 16
Four-Way Switch
20
INFORMATION SHEET
The four-way switch’s contact mechanisms can

operate the light independently of the three-way
switches. The drawing of figure 17 shows how the
internal contact mechanism works. From the circuit
you can see that any number of four-way switches
can be added to increase the number of control
points.
NEUTRAL LOCATION 1 LOCATION 2 LOCATION 3

THREE-WAY FOUR-WAY THREE-WAY
SWITCH SWITCH SWITCH
LINE
UP LAMP OFF
HANDLE UP
NEUTRAL
DOWN
LINE
LAMP ILLUMINATED
HANDLE DOWN
Figure 17
Four-Way Switching Internal Connections
RECEPTACLES
Receptacle are devices installed in an electrical Only explosion proof

circuit. They allow you to connect a power supply receptacles can be
used in hazardous
to an electrical appliance. They are usually made of areas.
plastic or other materials that do not conduct
electricity. There are many types of low voltage
receptacles, the most common in Saudi Arabia being:
❏ Single – has one outlet only. COVER PLATE
❏ Duplex – each receptacle has two outlets. Both

outlets receive power from the same circuit. A
duplex can be made into a split-duplex by
removal of the break-off tab.
❏ Split-duplex – each outlet can accept power UTILITY BOX
RECEPTACLE
from a separate circuit. A switch can control

Figure 18
one half of the receptacle. The other half of the Non-Explosion Proof Duplex
receptacle can remain permanently energized. Assembly
21
INFORMATION SHEET
These types of receptacles can be mounted on the

surface of a wall or partition or into an opening or
recess.
Voltage and Current Ratings
Note: The shape of the Receptacles have many different openings called
openings in the receptacle. sockets. Each socket arrangement indicates a
Only the correct matching plug
will fit the opening. This different voltage or current. Always use the correct
ensures that the correct matching plug with each receptacle. Refer to figure
voltage and current will be
connected between the 19 for some common low voltage receptacle sockets
receptacle and plug. and their voltage and current ratings.
CURRENT
15A 20A 30A
1 2 3
V 120V
O
L
T
A 4 5 6
G
E 240V
Figure 19
Receptacle Sockets
Example
A circuit requires a supply of 120 volts at a

The plug to fit receptacle No. 1
will also fit receptacle No. 2. maximum current of 20 amps. This circuit must use
This is because No. 1 has a receptacle number 2.
lower current rating than No. 2.
The plug to fit receptacle No. 4
will also fit receptacle No. 5.
This is because No. 4 has a
lower current rating than No. 5.
22
INFORMATION SHEET
Making Connections
The most common way for standard conductor-to-

After making a
receptacle connection is to wrap the wires under the connection you
terminal screws and tighten them in the direction of should not see any
bare wire.
the screw to tighten. However, different receptacles
need different connections. Some types have special
openings where you fit the wire ends and then
tighten the terminal screws. Other types require the
wire ends to have crimp or terminal lugs fitted to
the conductors.
Ensure you know the type of connection for

the receptacle you are working on.
PANELBOARD
A panelboard or panel is a type of box used to

enclose protective devices and conductors that supply Special sealed
explosive proof
electrical power to equipment and lighting circuits. panelboards (see
For example, the disconnect switches and CB’s you figure 20) must be
used in hazardous areas.
learned about earlier.
Panelboards are available for exterior and interior use

and for standard low-voltage or explosive proof
operation. They can be recessed in a wall or surface
mounted.
23
INFORMATION SHEET
TERMINALS
CB's
CB's
EXPLOSION-PROOF PANELBOARD
Figure 20
Panelboard Assembly’s
As panelboards can be
Typically, load distributor panelboards contain:
configured differently, this
section deals with general Neutral Busbar (Terminal): the connection point for
conductor color codes and the neutral from the power source and the load.
connections.
Ground Busbar (Terminal): the connection point for
the system and load-grounding conductors.
The busbar also grounds the
panelboard to the electrical Circuit Breaker Mountings: metal mounting racks
system ground. Grounding
bolts are sometimes used
for the circuit breakers.
instead of a busbar.
Bus Connections: terminals providing a way to
connect circuit breakers to the main busbars.
Phase Busbars: flat copper or aluminum bars that

provide power for the electrical loads. Insulated from
the metal parts of the panelboard. They are
connected to the main power circuit breaker. They
A single-phase panelboard
usually has two of these bars.
are energized continuously once the panelboard is
connected to a power source and the main circuit
breaker is closed.
Circuit Breakers: protect a circuit against excessive

current.
Main Power Terminals: connecting points for the

power source conductors entering the panelboard
from a distribution system.
24
INFORMATION SHEET
Connections
We will now look at some ways the panelboard can

be wired up and connected. For ease, we will use a
non-explosive type panelboard as our example.
Feeder Connections
To begin, three power source feeder conductors are

installed. These enter the panelboard from a switch
board or another panelboard.
The main power circuit breaker has two line

conductors connected. The white conductor or
neutral conductor is connected to the neutral busbar.
(See figure 21).
PHASE (LINE)
CONDUCTORS
NEUTRAL
CONDUCTOR
MAIN
BREAKER GROUNDING
CONDUCTOR
BRANCH
CIRCUIT
BREAKERS
GROUNDING
NEUTRAL BUSBAR
BUSBAR
Figure 21
Feeder Connections (Non-Explosion Proof Assembly)
25
INFORMATION SHEET
The grounding busbar terminal has the grounding

conductor connected. This may be uninsulated or
have green insulation. Grounding makes the
electrical system safe. If a fault occurs, it provides a
direct current path to ground. Figure 22 shows the
grounding conductor connected to the panelboard.
On grounded systems, the
neutral and ground conductors
The grounding screw on the neutral busbar connects
have the same potential. the bar to the grounding busbar for a neutralized
grounded system.
GROUNDING
CONDUCTOR
BOTTOM OF
PANEL BOARD
GROUNDING
BUSBAR
NEUTRAL
BUSBAR
Figure 22
Grounding the Panelboard (Non-Explosion Proof Assembly)
Branch Circuit Connections
Branch circuits are defined in Branch circuits serve general-purpose lighting,

the NEC - Article 100. This appliance, and individual circuits. Individual branch
states that a branch circuit is
the wiring between the final circuits serve such loads as:
protective device, (the last
circuit breaker or fuse) and the ❏ machine shop equipment
electrical load.
❏ small air compressors
❏ ventilation fans
❏ air conditioning equipment
26
INFORMATION SHEET
LIGHT OUTLET
GENERAL
PURPOSE
CIRCUIT
CIRCUIT RECEPTACLE
OUTLET INDIVIDUAL
BREAKERS
BRANCH
SWITCH
APPLIANCE CIRCUIT
BRANCH CIRCUITS
Figure 23
Branch Circuits and Individual Branch Circuits
Standard low-voltage branch circuits are color-coded Note: Not all manufacturers’
as defined in NEC Articles 200. These state that equipment leads are correctly
color coded. Always check.
ungrounded conductors be colored black, red or
blue. Grounded (neutral) conductors are white or
natural gray. The grounding conductor may be green
or uninsulated.
In the panelboard, the line conductor (black) of the

branch circuit is connected to the circuit breaker.
The neutral conductor (white) is connected to the
neutral bus terminal. The grounding conductor
(green) is connected to the grounding bus terminal.
Circuit breakers are connected to a phase busbar.

Each set of breakers to a different phase bus. Their
connections should alternated to balance the branch
circuit loads. They must be numbered to identify
the circuit they protect. The main circuit breaker
protects all the branch circuits. Therefore, must be
connected between the main power source feeder
conductors and the phase busbars.
27
INFORMATION SHEET
SUMMARY
In this part, you have studied how different types of

switch and switching circuits can be used to control
lighting. You learned the basics of wiring up
receptacles, and how their openings (sockets) are
defined by their voltage and current capacity. Then
you learned panelboard connection principles.
What you must remember is that there are many

different types of switches, receptacles and
panelboards. Therefore, you must always make sure
that you use only the type required for that location
and application.
28
INFORMATION SHEET
EXERCISE C
provided.
1. In ac circuits, on what conductor are switches

connected?
2. What is the drawing symbol for a single-pole

switch?
3. How can you make a duplex receptacle into a

split-duplex?
4. What important information do you know by

looking at a receptacles socket?
5. Exactly where would you find a listing of

branch circuit conductor color codes?
29
INFORMATION SHEET
PART IV OBJECTIVE 9.4.4
State the Use of Contactor Switching and

Photocells in Lighting Systems
So far, you have learned about light and receptacle

fixtures, conduit, and making connections. You must
now learn a little about remote switching circuits.
CONTACTOR SWITCHING
Contactors are made to prevent contacts from

overheating and welding closed under high current,
for example, the large initial currents created when
energizing HID and fluorescent fixtures.
Most switches operate at low current ratings.

Contactor (or relay switching) is used when:
❏ remote control of lighting is needed

Figure 24 ❏ lighting fixtures operate on high voltage
Lighting Contactor
❏ high current ratings are needed (large banks of
lights)
Remote Control Lighting Circuit
Refer to figure 25. Line voltage to the lighting

fixtures is 277 Vac. Control switch voltage is 24 Vac.
24 Vac through the control switch and relay,
controls the 277 Vac to the lighting fixtures.
30
INFORMATION SHEET
PART V OBJECTIVE 9.4.5
State the Safety Requirements Relating to the

Maintenance of Light Fixtures
In addition to the normal safety precautions you

must use when working on electrical equipment,
there are some special hazards you must be aware of
when maintaining lighting systems.
To begin, you must be aware that simply turning off

the light switch does not make the wiring safe. You
must always implement lockout procedures when
working on any electrical equipment or lighting
system.
STROBOSCOPIC EFFECT
Because fluorescent lighting flickers at the frequency

of the supply voltage (60Hz), you must be aware of
the dangers of stroboscopic effect.
This flickering (flashing on and off ) very quickly, is

invisible to the naked eye. By itself, this would be
no problem. However, the problems of stroboscopic
effect become clear when working near rotating
equipment. Flickering light on a piece of equipment
rotating at the same speed or a direct multiple of
the frequency (3600 rpm, 7200 rpm, etc.) makes the
equipment seem to stand still or even be turning
slowly in the opposite direction.
Because of this effect, you can easily become

disoriented into thinking a machine is not working.
This would be very dangerous.
40
INFORMATION SHEET
Stroboscopic effect can be overcome by use of two Lead-lag refers to making the
or more lamps in a fixture with lead-lag circuitry. ac cycles start and stop
differently for each tube.
The current cycle to one lamp leads, the other lags Phase shifting will be covered
(is behind). Using a capacitor in the circuit of one in detail in the next unit.
of the lamps can produce this phase difference. The

line supply can also be wired so that different phases
feed different fluorescent tubes. As a result, one
lamp will be turning on as the other turns off.
There are two more methods that prevent the

stroboscopic effect on rotating equipment:
❏ adding an incandescent light source close to the

rotating machinery
❏ ensuring that sufficient natural light falls on the
rotating equipment
HAZARDOUS CHEMICALS/GAS
Fluorescent tubes are coated with phosphor and

When working on
contain argon or mercury gas. HID lamp bulbs fluorescent or HID
contain mercury or sodium vapor. These chemicals lights, if you have an
accident, always
and elements are poisonous. seek medical advice.
You must take great care not to break the glass bulbs
or tubes. If dropped, they can explode causing
contaminated glass to fly in all directions.
When tubes and bulbs break there is also a problem

of the gas. If you breathe in the vapors they are also
poisonous.
41
INFORMATION SHEET
HEAT
One often-overlooked problem of working on many

light fixtures is that they become hot. Though
fluorescent fixtures remain quite cool, HID and
incandescent fixtures can become very hot. Make
sure fittings have cooled sufficiently before handling
them.
CHARGED SYSTEMS
Many ballast systems contain capacitors. When

power is removed, these components remain charged
for quite some time. Because of their function in the
ballast circuits, these capacitors can be charged to
high voltages. If you cause one to discharge
suddenly, for example, shorting its contacts with a
screwdriver (or your fingers), the sudden discharge
causes sparks, pain, and can even cause the capacitor
to blow up.
Whenever you work on a system containing

capacitive charge, you must always discharge the
power through a high resistive load (at least 1000Ω).
ULTRAVIOLET RADIATION
If the glass cover over the arc tube of an HID lamp

breaks, there is a danger of ultraviolet radiation.
Never look directly onto an unguarded tube, it will
damage your eyes. Also, never stand beneath an
unguarded tube. Ultraviolet radiation is what causes
sunburn. Because it does not feel hot, you can end
up by being badly burned.
42
INFORMATION SHEET
SUMMARY
In this module, you have learned to classify light

fixtures. You can now identify fluorescent and HID
types by sight, and by circuit operation. You have
also learned some basic control lighting circuits, how
they are physically wired up, the special control
components they use, and why they are used. To
complete this module, you learned some important
safety aspects of working on lighting systems.
In the task aid, you will put the knowledge you

have gained from this module to practical use. You
will replace a light fitting, then wire up and test the
lighting circuit.
43
INFORMATION SHEET
EXERCISE E
Part 1
provided.
1. What must you do before working on any

lighting system?
2. What is a problem of phosphor and mercury?
3. What must you do before working on

equipment with capacitors?
4. Why are different ac phases used to feed a

number of fluorescent tubes?
Part 2
Directions: Think of some safety aspects of maintaining
different lighting systems. Your instructor will ask you for
your thoughts in a class discussion.
44
TASK AID
REMOVE AND REPLACE A LIGHT FIXTURE

AND CONNECT A LIGHTING CIRCUIT
1. Open the work permit, perform lockout and

hold tag procedures and prepare the tools,
equipment and material you need.
2. Remove old light fitting.
3. Prepare cable ends for connection.
4. Perform insulation resistance tests between all

conductors.
5. Install and electrically connect the new HID

fitting.
6. Electrically connect the switch.
7. Make electrical connections to panelboard.
8. Perform continuity tests, and check routing

complies with wiring diagram.
9. Install switch assembly into the switch box and

replace all covers.
10. Remove your personal locks and hold tag.

Request your instructor check your work and
energize the circuit.
11. Perform houskeeping on your work area and

closeout the work permit.
46
ELECTRICAL
Module 9.5
INSTALL AND TEST A
LIGHTING SYSTEM IN
A HAZARDOUS
LOCATION
TABLE OF CONTENTS
Module 9.5
Install and Test a Lighting System in a Hazardous Location
TRAINEE HANDBOOK
INFORMATION SHEET
Enabling Objective
Terminal Objective
None. Given a work order, tools,e q
uipment, material and
diagrams, the trainee will
install and test fluorescent
and HID lighting systems.
The installed system
must meet NEC standards.
1
TASK AID
OBJECTIVE
Given a work order, tools, equipment, material and

diagrams, the trainee will repair and test
fluorescent and HID lighting systems. The
repaired system must meet NEC standards.
TOOLS AND EQUIPMENT

❑ electrician’s tool kit ❑ multimeter
❑ meg-ohmmeter ❑ HO 9.5-1
MATERIALS
❑ HID lamp fitting ❑ switch assembly
❑ wiring as required
SAFETY REQUIREMENTS
Ensure the work permit is opened, and hold tags Follow all workshop
and lockout procedures have been carried out before safety rules when
performing these task
starting the task. steps.
Wear safety shoes and safety glasses at all times.

Wear protective gloves to avoid sharp edges on
conduit and channel rack.
TASK INTRODUCTION
In this task aid, you will identify and rectify faults

on an HID lighting system. This will involve testing
and replacement of any defective items within the
lighting system.
5
TASK AID
INSTALL AND TEST A LIGHTING SYSTEM INA

HAZARDOUS LOCATION
1. Receive a hot work permit from your
instructor.
2. Prepare the tools, equipment and material you

need.
3. Check that all switches and CB’s are in the

off(denergized) position.
4. Check that the lamp illuminates. If not,

complete steps 5 and 6.
Take care not to touch 5. Deenergize CB’s and switches. Replace the lamp
the bulb with your bare fixture bulb.
hands.
6. Re-energize the CB’s and switches and test the

lamps operation. If it still fails to illuminate
complete steps 7 to 12.
7. Have your instructor deenergize the system.

In hazardous areas,
branch circuits must Perform lockout and attach a hold tag.
be de-energized before
opening any enclosures.
8. Install the additional part of the lighting
system
9. From your findings, locate and rectify the fault.
10. Check circuit again to confirm correct operation.

For reference, refer to
HO 9.4-1 wiring and
schematic diagrams. 11. Remove lockout and hold tag, energize the
system and check for correct operation.
12. Perform housekeeping on your work area and

close out the work permit.

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9 Month Certification Program

Install Lighting Systems

Unit 9: Install Lighting Systems

Use Electrical Test Equipment

So far, you have learned what electricity is and what

In part I, you will learn to identify and classify

PART I OBJECTIVE 9.1.1

Classify Multimeter Types

As an electrical craftsman, you will often need to

A multimeter is a piece of equipment with several

There are two types of multimeters, analog and

ANALOG SCALE DIGITAL SCALE

There are many different multimeter models. Each

To classify a multimeter you must first determine its

Once you know the type, you can classify a

The meter’s measurement range is important. You

Question: How do you find out a multimeter’s

Answer: There are two ways to check the range of a

Your instructor will now pass out some multimeter

You have now learned to classify multimeters by:

❏ type: digital or analog

You have also learned that to get specific

In the next part, you will learn how to use

PART II OBJECTIVE 9.1.2

State the Equipment Condition and Connection

To use any multimeter safely, there are some basic

❏ Measuring voltage: You must start by making

Note: As you measure voltage on live equipment,

❏ Measuring current: You want to measure the

FLUKE 87 TRUE ARMS MULTIMETER

MIN MAX RANGE HOLD H MIN MAX RANGE HOLD H

400mA MAX 400mA MAX

Selecting Meter Functions

Measuring current, you

Connecting Test Leads

Again, you must know what test lead connections

In this part, you have learned how to classify

You also learned one other important fact while

1. In what condition must equipment be to

2. How do you connect a multimeter for

3. Where do you check the range scale of a

4. How do you connect a multimeter to measure

5. When measuring resistance on de-energized

6. What must you do before connecting a

PART III OBJECTIVE 9.1.3

Identify the Parts and State the Uses of Electrical

ELECTRICAL TEST EQUIPMENT

❏ the meg-ohm meter

You will learn how to use these meters, along with

Dual = two or twin.

Meg-Ohm Meter Parts

❏ a clutch controlled, hand operated generator

Compare these features with the meg-ohm models

On the model shown in figure 5, turning the crank

The selector switch lets you select the meters output

Like the multimeters you used earlier, the meg-ohm

Commonly, analog type meg-ohm meters have two

On all meg-ohm meters, when measuring continuity,

The scale shows or indicates resistance values from