ELECTRICAL SHOP

Definition:
The indispensable and pervasive knowledge of electrical wiring and the electronic
circuits will give the students an insight to their practical approach in our daily life.

Electrical workshop tools:

 Steel Tape
A tape measure or measuring tape is a flexible ruler and used to measure distance. It
consists of a ribbon of cloth, plastic, fibre glass, or metal strip with linear-measurement
markings Surveyors use tape measures in lengths of over 100 m (300+ ft).

 Pliers:
Pliers are a hand tool used to hold objects firmly, possibly developed from tongs used to
handle hot metal in Bronze Age Europe. They are also useful for bending and
compressing a wide range of materials.
  Nose Pliers:
Needle-nose pliers are both cutting and holding pliers used by artisans, jewellery
designers, electricians, network engineers and other tradesmen to bend, re-position and
snip wire. Their namesake long nose gives excellent control while the cutting edge near
the pliers' joint provides "one-tool" convenience.

 Wire cutter:
Diagonal pliers (or wire cutters or diagonal cutting pliers or diagonal cutters or side
cutting pliers) are pliers intended for the cutting of wire. The plane defined by the cutting
edges of the jaws intersects the joint rivet at an angle or "on a diagonal", hence the
name.
  Screw driver:
A screwdriver is a tool that is used for turning screws. It consists of a metal rod with
a flat or cross-shaped end that fits into the top of the screw.

 Screw wrench:
A wrench is a tool used to provide grip and mechanical advantage in applying torque to
turn objects usually rotary fasteners, such as nuts and bolts or keep them from turning.

 Wire stripper:
A wire stripper is a small, hand-held device used to strip the electrical insulation from
electric wires.
  Digital multimeter:
A digital multimeter (DMM) is a test tool used to measure two or more electrical values
principally voltage (volts), current (amps) and resistance (ohms). It is a standard
diagnostic tool for technicians in the electrical/electronic industries.

 Test Light:
A test light, test lamp, voltage tester, or mains tester is a piece of
electronic test equipment used to determine the presence of electricity in a piece of
equipment under test Non-contact test lights can detect voltage on insulated
conductors.
Electrical cables:
An electrical cable, or power cable, is used to transmit electrical power. Electrical cables
provide connection and allow power stations, wired computer networks, televisions,
telephones and other electricity-powered devices to work. There are many types of
electrical cables that differ in configuration, size and performance.

Classification of cables:
1. According to core
2. According to insulation

According to core:

 Single core cable:

A single core wire is a cylindrical strand of metal. In single core wire there is only a
single core of metal is present, mostly copper or aluminum, and it generally has some
insulation around it. The wire can be different gauge, or thicknesses.
  Double core cable:
A wire is a double, usually cylindrical, flexible strand or rod of metal The term wire is
also used more loosely to refer to a bundle of such strands, as in "multistranded wire",
which is more correctly termed a wire rope in mechanics, or a cable in
electricity. Wire comes in solid core, stranded, or braided forms.

 Triple core cable:

These cables are used generally for a perfect balanced 3-phase system. When the
currents on the 3-live wires of a 3-phase system are equal and at an exact 120° phase
angle, then the system is said to be balanced. The 3-phase loads are identical in all
respects with no need of a neutral conductor.
  Fourth core cable:
When there is severe out-of-balance conditions, the amount of fault current will raise to
a very high level. Generally in the case of linear loads, the neutral only carries the
current due to imbalance between the phases.

According to insulation:
 P.V.C
PVC (Polyvinyl Chloride) is the most commonly used thermoplastic insulator for cables.
It is cheap, durable and widely available. However, the chlorine in PVC (a halogen)
causes the production of thick, toxic, black smoke when burnt and can be a health
hazard in areas where low smoke and toxicity are required (e.g. confined areas such as
tunnels). Normal operating temperatures are typically between 75C and 105C.
  Thermosetting (XLPE)
XLPE (Cross-Linked Polyethylene) has different polyethylene chains linked together
which helps prevent the polymer from melting or separating at elevated temperatures.
Therefore XLPE is useful for higher temperature applications. XLPE has higher
dielectric losses than PE, but has better ageing characteristics and resistance to water
treeing. Normal operating temperatures are typically between 90C and 110C.
Temperature limit is 250C.

 Paper based
Paper Based insulation is the oldest type of power cable insulation and is still used
mainly for high voltage cables. The paper insulation must be impregnated with a
dielectric fluid (e.g. oil resin or a synthetic fluid). A lead sheath is commonly applied over
the insulation to prevent water or moisture ingress into the paper insulation, which is
sensitive to moisture.
  Rubber
V.I.R. wires-(Vulcanized India Rubber) In this type of wire a tinned copper conductors or
aluminum conductors are used. The conductors are covered by Vulcanized India
Rubber. It is then covered with cotton tape and cotton braiding.

 Mineral
Mineral-insulated copper-clad cable is a variety of electrical cable made from copper
conductors inside a copper sheath, insulated by inorganic magnesium oxide powder.
The name is often abbreviated to MICC or MI cable, a similar product sheathed with
metals other than copper is called mineral insulated metal sheathed (MIMS) cable.

Electrical wiring:
Electrical wiring is an electrical installation of cabling and associated devices such as
switches, distribution boards, sockets and light fittings in a structure. Wiring is subject to
safety standards for design and installation.
Types of wiring:
 Cleat Wiring
This system of wiring comprises of ordinary VIR or PVC insulated wires (occasionally,
sheathed and weather proof cable) braided and compounded held on walls or ceilings
by means of porcelain cleats, Plastic or wood. Cleat wiring system is a temporary wiring
system therefore it is not suitable for domestic premises. The use of cleat wiring system
is over nowadays.

Advantages of Cleat Wiring:

 It is simple and cheap wiring system
 Most suitable for temporary use i.e. under construction building or army camping
 As the cables and wires of cleat wiring system is in open air, therefore cables can
be seen and repairs easily.
 Cleat wiring system installation is easy and simple.

Disadvantages of Cleat Wiring:

 Appearance is not so good.
 Cleat wiring can’t be use for permanent use because; Sag may be occur after
sometime of the usage.
 In this wiring system, the cables and wiring is in open air, therefore,
oil, Steam, humidity, smoke, rain, chemical and acidic effect may damage the
cables and wires.

 It is not lasting wire system because of the weather effect, risk of fire and wear &
tear.
  Casing and Capping wiring
Casing and Capping wiring system was famous wiring system in the past but, it is
considered obsolete this days because of Conduit and sheathed wiring system. The
cables used in this kind of wiring were either VIR or PVC or any other approved
insulated cables. The cables were carried through the wooden casing enclosures. The
casing is made up of a strip of wood with parallel grooves cut length wise so as to
accommodate VIR cables. The grooves were made to separate opposite polarity. the
capping (also made of wood) used to cover the wires and cables installed and fitted in
the casing.

Advantages of Casing Capping Wiring:

 It is cheap wiring system as compared to sheath and conduit wiring systems.
 It is strong and long-lasting wiring system.
 Customization can be easily done in this wiring system.
 If Phase and Neutral wire is installed in separate slots, then repairing is easy.

Disadvantages Casing Capping Wiring:

 There is a high risk of fire in casing & capping wiring system.
 Not suitable in the acidic, alkalies and humidity conditions
 Costly repairing and need more material.
 Material can’t be found easily in the contemporary
Batten Wiring
Single core or double core or three core TRS cables with a circular oval shape cables
are used in this kind of wiring. Mostly, single core cables are preferred. TRS cables are
chemical proof, water proof, steam proof, but are slightly affected by lubricating oil. The
TRS cables are run on well seasoned and straight teak wood batten with at least a
thickness of 10mm.

Advantages of Batten Wiring:

 Wiring installation is simple and easy
 cheap as compared to other electrical wiring systems
 Paraphrase is good and beautiful
 Repairing is easy

Disadvantages of Batten Wiring:

 Can’t be install in the humidity, Chemical effects, open and outdoor areas.
 High risk of firs
 Not safe from external wear & tear and weather effects (because, the wires are
openly visible to heat, dust, steam and smoke.
 Heavy wires can’t be used in batten wiring system.
  Conduit Wiring
A conduit is a tube used to protect and route electrical wiring in a building or structure.
Electrical conduit may be made of metal, plastic, fiber, or fired clay. Most conduit is
rigid, but flexible conduit is used for some purposes. Conduit is generally installed
by electricians at the site of installation of electrical equipment.

Advantage of Conduit Wiring :

 It is the safest wiring system (Concealed conduit wring)
 Appearance is very beautiful (in case of concealed conduit wiring)
 No risk of mechanical wear & tear and fire in case of metallic pipes.
 Customization can be easily done according to the future needs.
 Repairing and maintenance is easy.

Disadvantages of Conduit Wiring:

 It is expensive wiring system (Due to PVC and Metallic pipes, Additional earthing
for metallic pipes Tee(s) and elbows etc.
 Very hard to find the defects in the wiring.
 Installation is not easy and simple.
 Risk of Electric shock (In case of metallic pipes without proper earthing system)
 Very complicated to manage additional connection in the future.
Types of Conduit:
 Metallic Conduit
Metallic conduits are made of steel which are very strong but costly as well.

There are two types of metallic conduits.

 Class A Conduit: Low gauge conduit (Thin layer steel sheet conduit)
 Class B Conduit: High gauge conduit (Thick sheet of steel conduit)

Non-metallic Conduit:
A solid PVC conduit is used as non-metallic conduit now a days, which is flexible and
easy to bend.

Size of Conduit:
The common conduit pipes are available in different sizes genially, 13, 16.2, 18.75, 20,
25, 37, 50, and 63 mm (diameter) or 1/2, 5/8, 3/4, 1, 1.25, 1.5, and 2 inch in diameter.

Electrical Accessories:
Switch:
Electrical switches are very simple devices that are used to turn things on and off. The
most common type of switches is the one that we use to turn our lights on and off.
  Single way switch:
A one-way switch only has two contacts while A one-way switch basically operates as a
make or break switch.

 Two way switch:

2 way switching means having two or more switches in different locations to control one
lamp. They are wired so that operation of either switch will control the light. This
arrangement is often found in stairways, with one switch upstairs and one switch
downstairs or in long hallways with a switch at either end.
  Toggle switch:
A toggle switch is manually actuated (or pushed up or down) by a mechanical handle,
lever or rocking mechanism. These are commonly used as light control switches.

Bulb holder:
A bulb holder is a device that holds a bulb the image below shows a bulb holder from a
ceiling light. The bulb fits into the bulb holder; the bulb holder 'holds' the bulb. The bulb
holder contains the electrical connection from the supply to the bulb.
Fuse:
a fuse is an electrical safety device that operates to provide overcurrentprotection of an
electrical circuit. Its essential component is a metal wire or strip that melts when too
much current flows through it, thereby interrupting the current. It is a sacrificial device;
once a fuse has operated it is an open circuit, and it must be replaced or rewired,
depending on type.

Circuit breaker:
A circuit breaker is an automatically operated electrical switch designed to protect
an electrical circuit from damage caused by excess current from an overload or short
circuit. Its basic function is to interrupt current flow after a fault is detected.