Professional Documents
Culture Documents
Chapter one
Introduction
Electrical safety rules
Electrical Tools
Chapter Two
Wire splicing and Termination
Chapter Three
General soldering
Chapter four
Residential Installation
Industrial Installation
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Chapter One
Health & Safety - Electricity at Work
Each year about 1000 accidents at work involving electric shock or burns are reported to the
Health & Safety Executive (HSE). About 30 of these are fatal, however nearly a quarter of all
reportable electrical accidents involve portable equipment. Those using electricity may not be the
only ones at risk: poor electrical installations and faulty electrical appliances can lead to fires
which may also cause death or injury to others. Most accidents can be avoided by careful
planning and straight forward precautions. The main duty of employers is to identify the hazard
and reduce the risk of the hazard occurring.
WORKSHOP SAFETY
Safety in the workshops is subject to a number of various risk assessments and safe codes of
working practices which have to be observed and adhered to by all workshop users and enforced
by the person in charge of these areas. Due to high risk activities taking place in the workshops
access to these areas is restricted to authorized personnel only. No other person may enter the
workshops without permission.
Equipment must be cleaned after use. Any materials, tools or equipment used must be
tidied away.
Precision measuring equipment, drills, etc. must be replaced in their appropriate cabinets
after each working day.
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Tools and equipment must not be removed from the workshop without permission from
the technician-in-charge.
Electrical TOOLS
Combination Pliers : Used for holding, twisting or cutting of wires.
Side cutting Plier: Used for Cutting at narrow places or ordinary places for removing
insulation.
Round Nose Plier or Flat Nose Plier: Used for holding, twisting or joining the wire at narrow
places.
Tenon saw or back Saw: Used for cutting wooden boards, Block casting etc.
Hack saw: Used for cutting conduit GI pipes or mild steel.
Mallet: Used as a hammer and made of wood
Electric knife: removing insulation of wires
Line Tester: Used for testing the current.
Royal Plug Tool: It is made of steel and is used for making holes in the stone wall or concrete
wall for fiber made Royal plugs.
Screw driver: Used for loosening, tightening and to keep the screws in position.
Ball Peen Hammer: Used for fitting nails in the walls or wooden boards.
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Chapter Two
Wire splicing and termination
Materials solid wire, pliers side cuter insulation remover, Electrical knife
Introduction
In all jobs of wiring splicing (jointing ) and termination is a necessity. The jointing
is required since the wires are manufactured in 100 metes lengths and the total
length of wires used for house wiring may be more than 100 meters the termination
of wires is needed, as the wires are to be connected to switches holders receptacles
etc. it is important to note that all point made must be mechanically and electrically
sound.
The jointing
TYPES OF SPLICES
This time I will explain the techniques usual to splices conductor in electrical works.
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1) Western Union Splice
o Prepare the wires for splicing. Enough insulation is removed to make the splice. The
conductor is cleaned.
o Bring the wires to a crossed position and make a long twist or bend in each wire
o Wrap one end of the wire and then the other end four or five times around the straight
portion of each wire
o Press the ends of the wires down as close as possible to the straight portion of the wire.
This prevents the sharp ends from puncturing the tape covering that is wrapped over the splice.
2) Staggering Splices
Joining small multiconductor cables often presents a problem. Each conductor must be spliced
and taped. If the splices are directly opposite each other, the overall size of the joint becomes
large and bulky. A smoother and less bulky joint can be made by staggering the splices.
Care should be taken to ensure that a short wire from one side of the cable is spliced to a long
wire, from the other side of the cable. The sharp ends are then clamped firmly down on the
conductor.
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3) Rattail Joint
A splice that is used in a junction box and for connecting branch circuits is the rattail joint.
Wiring that is installed in buildings is usually placed inside long lengths of steel or aluminum
pipe called a conduit.
Whenever branch or multiple circuits are needed, junction boxes are used to join the conduit. To
create a rattail joint, first strip the insulation off the ends of the conductors to be joined. You then
twist the wires to form the rattail effect. This type of splice will not stand much stress.
All the splices discussed up to this point are known as butted splices. Each was made by joining
the free ends of the conductors together. Sometimes, however, it is necessary to join a branch
conductor to a continuous wire called the main wire. Such a junction is called a tap joint.
The main wire, to which the branch wire is to be tapped, has about 1 inch of insulation removed.
The branch wire is stripped of about 3 inches of insulation.
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Step :
o The branch wire is laid behind the main wire. About three-fourths of the bare portion of
the branch wire extends above the main wire.
o The branch wire is brought under the main wire, around itself.
o Then over the main wire to form a knot. The branch wire is then wrapped around the
main conductor in short.
o Tight turns; and the end is trimmed off.
The knotted tap is used where the splice is subject to strain or slippage. When there is no strain,
the knot may be eliminated.
Chapter Three
Lab 2 Soldering
Soldering is defined as "the joining of metals by a fusion of alloys which have relatively low
melting points". In other words, you use a metal that has a low melting point to adhere the
surfaces to be soldered together. Consider that soldering is more like gluing with molten metal,
unlike welding where the base metals are actually melted and combined. Soldering is also a must
have skill for all sorts of electrical and electronics work. It is also a skill that must be taught
correctly and developed with practice.
This tutorial will cover the most common types of soldering required for electronics work. This
includes soldering components to printed circuit boards and soldering a spliced wire joint.
Soldering Equipment
The Soldering Iron
The first thing you will need is a soldering iron, which is the heat source used to melt solder.
Irons of the 15W to 30W range are good for most electronics/printed circuit board work.
Anything higher in wattage and you risk damaging either the component or the board. If you
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intend to solder heavy components and thick wire, then you will want to invest in an iron of
higher wattage (40W and above) or one of the large soldering guns. The main difference between
an iron and a gun is that an iron is pencil shaped and designed with a pinpoint heat source for
precise work, while a gun is in a familiar gun shape with a large high wattage tip heated by
flowing electrical current directly through it.
For hobbyist electronics use, a soldering iron is generally the tool of choice as its small tip and
low heat capacity is suited for printed circuit board work (such as assembling kits). A soldering
gun is generally used in heavy duty soldering such as joining heavy gauge wires, soldering
brackets to a chassis or stained glass work.
You should choose a soldering iron with a 3-pronged grounding plug. The ground will help
prevent stray voltage from collecting at the soldering tip and potentially damaging sensitive
(such as CMOS) components. By their nature, soldering guns are quite "dirty" in this respect as
the heat is generated by shorting a current (often AC) through the tip made of formed wire. Guns
will have much less use in hobbyist electronics so if you have only one tool choice, an iron is
what you want. For a beginner, a 15W to 30W range is the best but be aware that at the 15W end
of that range, you may not have enough power to join wires or larger components. As your skill
increases, a 40W iron is an excellent choice as it has the capacity for slightly larger jobs and
makes joints very quickly. Be aware that it is often best to use a more powerful iron so that you
don't need to spend a lot of time heating the joint, which can damage components.
A variation of the basic gun or iron is the soldering station, where the soldering instrument is
attached to a variable power supply. A soldering station can precisely control the temperature of
the soldering tip unlike a standard gun or iron where the tip temperature will increase when idle
and decrease when applying heat to a joint. However, the price of a soldering station is often ten
to one hundred times the cost of a basic iron and thus really isn't an option for the hobby market.
But if you plan to do very precise work, such as surface mount, or spend 8 hours a day behind a
soldering iron, then you should consider a soldering station.
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The rest of this document will assume that you are using a soldering iron as that is what the
majority of electronics work requires. The techniques for using a soldering gun are basically the
same with the only difference being that heat is only generated when the trigger is pressed.
Solder
The choice of solder is also important. There several kinds of solder available but only a few are suitable
for electronics work. Most importantly, you will only use rosin core solder. Acid core solder is common in
hardware stores and home improvement stores, but meant for soldering copper plumbing pipes and not
electronic circuits. If acid core solder is used on electronics, the acid will destroy the traces on the
printed circuit board and erode the component leads. It can also form a conductive layer leading to
shorts.
For most printed circuit board work, a solder with a diameter of 0.75MM to 1.0MM is desirable.
Thicker solder may be used and will allow you to solder larger joints more quickly, but will
make soldering small joints difficult and increase the likelihood of creating solder bridges
between closely spaced PCB pads. An alloy of 60/40 (60% tin, 40% lead) is used for most
electronics work. These days, several lead-free solders are available as well. Kester "44" Rosin
Core solder has been a staple of electronics for many years and continues to be available. It is
available in several diameters and has a non-corrosive flux.
Large joints, such as soldering a bracket to a chassis using a high wattage soldering gun,will
require a separate application of brush on flux and a thick diameter solder of several millimeters.
Remember that when soldering, the flux in the solder will release fumes as it is heated. These
fumes are harmful to your eyes and lungs. Therefore, always work in a well ventilated area and
avoid breathing the smoke created. Hot solder is also dangerous. It is surprisingly easy to splash
hot solder onto yourself, which is a thoroughly unpleasant experience. Eye protection is also
advised.
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Chapter Four
RESIDENTIAL INSTALLATION
Graphical symbol for electrical installation
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Lab 3 Fluorescent lamp
What are fluorescent lamps?
There are various sizes and types of fluorescent lamps. Typically four and eight-foot long lamps
are used in homes, offices, and institutions. High-intensity discharge (HID) lamps such as
mercury vapor, metal halide, neon and high pressure sodium lamps are commonly used by
farms, businesses and cities.
Fluorescent lamps are long-lasting and energy efficient when compared to standard light bulbs.
Future use is expected to increase. Some manufacturers are now producing more energyefficient
lamps with less mercury.
Original preheat circuit uses a starter. When starter
switch is closed, current runs through and heats
cathodes. When arc through tube is established,
switch opens.
However, more power is required to start a fluorescent lamp than to maintain it. Preheat fixtures
get their name from a starting circuit that sends increased current through the cathodes to heat
their coated filaments. The heated cathodes send a high-voltage pulse along the tube that creates
an arc through the mercury vapor. As the atmosphere inside the tube heats up, electron activity
increases to its most efficient, ballast-sustained level, and the mercury vapor carries the current
on its own. The starting circuit is controlled by a starter switch that opens after a short preheat
period (see preheat starter circuit diagram).
A variation of the starter-switch concept can be found in small desk lamps. Here, however, the
starter switch is manual you simply hold down the switch button until enough heat is generated
to sustain the arc through the mercury vapor.
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What’s Inside a Fluorescent Tube Light?
A fluorescent lamp basically consists of a long glass gas discharge tube. Its inner surface
is coated with phosphorous and is filled with an inert gas, generally argon, with a trace of
mercury.
The tube is then finally sealed at low pressure with two filament electrodes each at its
both ends.
These electrode filaments are used to preheat the tube and initiate a rapid conduction of
electrons between the two end electrodes. The process initially requires a relatively high
amount of power.
Once the conduction of electrons between the electrodes is complete, no more heating of
the filaments is required and whole system works at a much lower current.
Class work
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Lab 4 . Lighting fixture controlled at one position
Wiring diagram
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Lab 5 . Lighting fixture controlled at one position
Lab 6 . Two lamp controlled at one position using single double pole switch
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Lab 7 . One lamp controlled at two positions
Assignment
1. Three lamp controlled at one position using single triple pole switch .
2. Two lamp controlled at one position using single one way switch .
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5. Tree lamps controlled at three positions.
6. Draw the wiring diagram for the following lay out diagram. Lamp A controls S1, S2and S3,
lamp B controls S4. [S - switch ]
INDUSTRIAL INSTALLATION
A contactor is an electrically controlled switch used for switching a power circuit, similar to a
relay except with higher current ratings, A contactor is controlled by a circuit which has a much
lower power level than the switched circuit.
Contactors are used to control electric motors, lighting, heating, capacitor banks, and other
electrical loads
A contactor has three components. The contacts are the current carrying part of the contactor.
This includes power contacts, auxiliary contacts, and contact springs. The electromagnet (or
"coil") provides the driving force to close the contacts. The enclosure is a frame housing the
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contact and the electromagnet. Enclosures are made of insulating materials like Bakelite,
Nylon 6, and thermosetting plastics to protect and insulate the contacts and to provide some
measure of protection against personnel touching the contacts. Open-frame contactors may have
a further enclosure to protect against dust, oil, explosion hazards and weather.
Magnetic blowouts use blowout coils to lengthen and move the electric arc. These are especially
useful in DC power circuits. AC arcs have periods of low current, during which the arc can be
extinguished with relative ease, but DC arcs have continuous high current, so blowing them out
requires the arc to be stretched further than an AC arc of the same current. The magnetic
blowouts in the pictured Albright contactor (which is designed for DC currents) more than
double the current it can break, increasing it from 600 A to 1,500 A.
Sometimes an economizer circuit is also installed to reduce the power required to keep a
contactor closed; an auxiliary contact reduces coil current after the contactor closes. A somewhat
greater amount of power is required to initially close a contactor than is required to keep it
closed. Such a circuit can save a substantial amount of power and allow the energized coil to stay
cooler. Economizer circuits are nearly always applied on direct-current contactor coils and on
large alternating current contactor coils.
A basic contactor will have a coil input (which may be driven by either an AC or DC supply
depending on the contactor design). The coil may be energized at the same voltage as the motor,
or may be separately controlled with a lower coil voltage better suited to control by
programmable controllers and lower-voltage pilot devices. Certain contactors have series coils
connected in the motor circuit; these are used, for example, for automatic acceleration control,
where the next stage of resistance is not cut out until the motor current has dropped
Operating principle
When current passes through the electromagnet, a magnetic field is produced, which attracts the
moving core of the contactor. The electromagnet coil draws more current initially, until its
inductance increases when the metal core enters the coil. The moving contact is propelled by the
moving core; the force developed by the electromagnet holds the moving and fixed contacts
together. When the contactor coil is de-energized, gravity or a spring returns the electromagnet
core to its initial position and opens the contacts.
For contactors energized with alternating current, a small part of the core is surrounded with a
shading coil, which slightly delays the magnetic flux in the core. The effect is to average out the
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alternating pull of the magnetic field and so prevent the core from buzzing at twice line
frequency.
The contactor is operated by the control circuit energizing a coil, which can be controlled by any
sort of switching device (to perform an assortment of tasks). When the coil is energized, the
circuit that the contactor is switching will be energized.
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Autotransformer starting
Reactor or resistor starting
A direct on line starter, often abbreviated DOL starter, is a widely-used starting method of
electric motors. The term is used in electrical engineering and associated with electric motors.
There are many types of motor starters, the simplest of which is the DOL starter.
To start, the contactor is closed, applying full line voltage to the motor windings. The motor will
draw a very high inrush current for a very short time, the magnetic field in the iron, and then the
current will be limited to the Locked Rotor Current of the motor. The motor will develop Locked
Rotor Torque and begin to accelerate towards full speed.
As the motor accelerates, the current will begin to drop, but will not drop significantly until the
motor is at a high speed, typically about 85% of synchronous speed. The actual starting current
curve is a function of the motor design, and the terminal voltage, and is totally independent of
the motor load.
The motor load will affect the time taken for the motor to accelerate to full speed and therefore
the duration of the high starting current, but not the magnitude of the starting current.
Provided the torque developed by the motor exceeds the load torque at all speeds during the start
cycle, the motor will reach full speed. If the torque delivered by the motor is less than the torque
of the load at any speed during the start cycle, the motor will stops accelerating. If the starting
torque with a DOL starter is insufficient for the load, the motor must be replaced with a motor
which can develop a higher starting torque.
The acceleration torque is the torque developed by the motor minus the load torque, and will
change as the motor accelerates due to the motor speed torque curve and the load speed torque
curve. The start time
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Control circuit power circuit Indicating circuit
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The parts of the forward reverse electric motor control (ckt) circuit include:
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Forward Reverse Power Circuit
The electrical schematic diagram on the right which features a CAD drawing provides an
illustration of the power circuit of a forward reverse motor controller used in every electrical
industry involving industrial process automation control technology. The diagram appears
similar to the DOL motor controller except for an additional reverse contactor connected in
parallel across the forward contactor.
The main circuit breaker is the main power supply switch that provides power to the line side
terminals L1, L2, L3 of the two contactors, awaiting for any of these two contactors to close to
deliver the voltage to the terminal of the motor U1, V1, W1 in order to run the motor.
The forward contactor is configured in such a way as to run the motor to its normal forward
rotation with L1 connected to U1, L2 to V1, and L3 to W1. Whereas the configuration of the
reverse contactor is wired in contrast to the configuration of the forward contactor so as to
provide a reverse rotation of the motor, with L1 to W1 instead U1, then L3 to U1 instead of W1,
while maintaining L2 connected to V1.
The thermal overload relay provides motor overload protection which detects motor overload
current to shut down the control system of the forward reverse motor controller. The forward
reverse motor control circuit controls the forward reverse power circuit which is presented and
discussed in the next article
After pushing the ON push button switch, the auxiliary contact of the main contactor coil which
is connected in parallel across the ON push button will close, thereby providing a latch to hold
the main contactor coil activated which eventually maintains the control circuit active even after
releasing the ON push button switch. Another auxiliary contact of the main contactor placed on
top of the star contactor coil and the timer coil initializes the control circuit which activates the
star connection of the motor through the star contactor coil, and while also awaiting to reach the
specified time delay along with the activation of the timer coil during this initial sequence. Once
the time delay is reached, the timer's auxiliary contacts will change state opposite its normal
condition which would become an open contact (instead of close) to release the star contactor
coil while at the same time providing a close contact (instead of open) to activate the delta
contactor coil for the second sequence to reconfigure the motor terminal connection from star to
delta connection, to place the motor in the run state from start state. A normally close auxiliary
contact from both star and delta contactors are also placed opposite of both star and delta
contactor coils, these interlock contacts serves as safety switches to prevent simultaneous
activation of both star and delta contactor coils, so that one cannot be activated without the other
deactivated first. Thus, the delta contactor coil cannot be active when the star contactor coil is
active, and similarly, the star contactor coil cannot also be active while the delta contactor coil is
active.
The control circuit above also provides two interrupting contacts to shutdown the motor. The
OFF push button switch is a manual operator access switch intended for shutting OFF the circuit
to stop the motor when necessary. The thermal overload contact is a protective device which
automatically opens the circuit in case when motor overload current is detected by the thermal
overload relay, this is to prevent burning of the motor in case of excessive load beyond the rated
capacity of the motor is detected by the thermal overload relay.
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Lab 11. Sequential motor starting system
Controlling diagram
Power diageram
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Lab 12. Control Circuit of a Star Delta or Wye Delta Electric Motor Controller
Controlling the interchanging star connection and delta connection of an AC induction motor is
achieved by means of a star delta or wye delta control circuit. The control circuit consists of push
button switches, auxiliary contacts and a timer to act on the conditional contact point logic and
time duration which upon reaching a specified time period would provide the switching sequence
of the magnetic contactors configured specifically for a star connection and a delta connection of
the motor terminals.
Power Circuit of a Star Delta or Wye Delta Electric Motor Controller - A basic how to
guide
Reduction of the AC induction motor's starting inrush current is achieved by implementing an
interchanging star delta or a wye delta connection of the motor, this can be done by incorporating
a configured star delta connection of the motor by using magnetic contactors or magnetic starter
switches. The diagram below illustrates this type of motor switching connection used in every
electrical industry involving industrial process automation control technology.
The main circuit breaker serves as the main power supply switch that supplies electricity to the
power circuit.
The main contactor connects the reference source voltage L1, L2, L3 to the primary terminal of
the motor U1, V1, W1.
The star contactor serves to initially short the secondary terminal of the motor U2, V2, W2 for
the start sequence during the initial run of the motor from standstill. This provides one third of
DOL current to the motor, thus reducing the high inrush current inherent with large capacity
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motors at startup.
The star delta power circuit presented here is controlled by the star delta control circuit which
provides the command for the required operational sequence, and from which, after a specified
time interval wherein the motor has finally developed sufficient inertia with a reduced inrush
starting current, the control circuit automatically transfers command from the start sequence to
the run sequence. This is achieved by reaching the specified time delay from a timer that
provides the switching from the star (start) contactor to the delta (run) contactor, wherein the star
contactor is deactivated and activating the delta contactor while maintaining the main contactor
energized all throughout the entire running duration of the electric motor. A full line voltage is
connected to the motor during the final stage of delta (run) sequence, which also supplies the line
voltage L1, L2, L3 to the secondary terminal of the motor U2, V2, W2, hence achieving the full
power and torque required for maximum efficiency of the motor
Assignment
Draw the circuit diagram, power diagram and lighting(indicating) diagram of Forward Reverse
and star (wye) delta motor controller system.
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