ELECTRICAL

WIRING
AND SOLDERING
 Engineering Workshop Practice Manual

Electrical safety precautions:

1. Avoid contact with energized electrical circuits.
2. Disconnect the power source before servicing or repairing electrical equipment.
3. When it is necessary to handle equipment that is plugged in, be sure hands are dry
and, when possible, wear nonconductive gloves and shoes with insulated soles.
4. If it is not unsafe to do so, work with only one hand, keeping the other hand at your
side or in your pocket, away from all conductive material. This precaution reduces the
likelihood of accidents that result in current passing through the chest cavity.
5. If water or a chemical is spilled onto equipment, shut off power at the main switch or
circuit breaker and unplug the equipment.
6. If an individual comes in contact with a live electrical conductor, do not touch the
equipment, cord or person. Disconnect the power source from the circuit breaker or
pull out the plug using a leather belt.
7. Do not make circuit changes or perform any wiring when power is on.
8. Do not wear loose-fitting clothing or jewellery in the lab. Rings and necklaces are
usual excellent conductors in contact with your skin.
9. It is wise in electrical labs to wear pants rather than shorts or skirts.
10. Powered equipment can be hot! Use caution when handling equipment after it hasbeen
operating.
11. Do your wiring, setup, and a careful circuit checkout before applying power.
12. Use wires of appropriate length. Do not allow them to drape over your equipment.
13. Do not pull wires out until you are absolutely sure that the circuit is completely dead.
Shocks can occur if an inductive load (motor or transformer) is disconnected while
conducting.
14. All the electrical equipment must be connected to the proper earth line.
15. All high voltage equipment must properly be marked and danger signs displayed.
16. If you are working on high voltage circuits, have a co-worker along with you who knows
how to break the circuit to get you free and how to give you mouth-to-mouth resuscitation
and closed chest heart massage.
17. When you are mentally or physically tired, avoid work on energized circuits.

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Electrical Wiring Tools

1. Screw driver:
It is used to turn, tighten or remove screws.

2. Ratchet:
It is used to allow rotary motion in only one direction and preventing the motion in
opposite direction. It is used to tighten nuts of various sizes.

3. Wire cutter and plier:

A wire cutter is used for striping and cutting wires whereas a plier is used to hold objects
like nuts and bolts firmly also used for cutting metal wires.

4. Tester:
It is used to verify the presence of electric voltage in electrical equipment.

5. Crimping tool:
It is used to cut various objects such as wires, cords, tapes and so on. It is also used to join
wires with metal or plastic objects.

6. Voltmeter:
It is used to measure potential difference between two points in the electric circuit.

7. Ammeter:
It is used to measure current flow in a circuit.

8. Watt meter:
It is used to measure electrical power of any given circuit (in watts).

9. Megger or Megohmmeter:
It is used to measure leakage in wires and earth resistance.

10. Multimeter:
It is used to measure various electrical quantities like resistance, voltage, current, etc.

11. Energy Meter:

The meter which is used for measuring the energy utilises by the electric load is known as
the energy meter. The energy is the total power consumed and utilised by the load at a
particular interval of time. It is used in domestic and industrial AC circuit for measuring
the power consumption.
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12. Combination Pliers

It is used for cutting, removing insulation, jointing and twisting the electric wires and
cables even on live-line. A lineman’s pliers have special design, which multiplies force
through leverage. These pliers usually have grips for better handling than bare metal
handles. The grips also have insulation for protection against electric shock when working
with live circuits. A lineman’s pliers are typically machined from forged steel. The two
handles are precisely joined with a heavy-duty rivet that maintains the pliers’ accuracy
even after repeated use under extreme force on heavy gauge wire.

13. Electric Drilling Machine

It has the below mentioned properties: It is a portable electric powered tool used for
drilling the surface. It has a high-speed motor to revolve the chuck. It is used to make
holes smoothly and easily.

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 Engineering Workshop Practice Manual

Fuse Switch

+
Battery Load
-

Fig.1

Fig.2

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 Engineering Workshop Practice Manual

Electric circuit
An electric circuit is defined as the network of different components such as battery, lamp,
switch etc which facilitate current flow. Fig.1 and Fig.2 shows simple electric circuits.
Generally an electric circuit may have five components as listed below.
1. The power source. or battery.
2. Load.
3. Conductors.
4. Control devices.
5. Protective devices.

Human Sensitivity to Electricity

500mA – Immediate cardiac arrest resulting in death.

70-100mA – Cardiac fibrillation; the heart begins beats at a steady.
20-30mA – Muscle contraction can cause respiratory paralysis.
10mA – Muscle contraction; the person remains stuck, to the conductor.
1-9mA – Prickling sensation

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Electrical wiring accessories

Wiring accessories are used for connecting appliances

1. Switch

A switch is used to make or break an electrical circuit. It is used to switch ‘on’ or ‘off ’
the supply of electricity to an appliance. There are various switches

a. Surface switch:

It is mounted on wooden boards fixed on the surface of a wall. It is of three types

1. One-way switch 2. Two-way switch 3. Intermediate switch

One-way switch : It is used to control single circuits and lamp

Two-way switch : It is used to divert the flow of current to either of two

directions. The two-way switch can also be used to control
one lamp from two different places as in the case of staircase
wiring

Intermediate switch : It is used to control a lamp from more than two locations

b. Flush switch:

It used for decorative purpose

c. Bed switch:

As the name indicates, it is used to switch ‘on’ the light from any place, other than
switch board or from near the bed. This switch is connected through a flexible wire.

2. Holders

A holder is a device used for holding lamps firmly.

They are two types.

1. Pendant holder 2. Batten holder

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3. Ceiling Rose

It is used to provide a tapping to the pendant lamp– holder through the flexible wire or a
connection to a fluorescent tube.

4. Socket Outlet/Plug

The socket outlet has an insulated base with the moulded or socket base having three
terminal sleeves.

Types of wiring

1. Cleat Wiring

In this system of internal wiring the cables are used either VIR or PVC type. The
cables are held by porcelain cleats about 6mm above the walls or ceiling. The cleats are
made in two halves, one base and the other cap. The base is grooved to accommodate the
cables and the cap is put over it and whole of it is then screwed on wooden plugs previously
cemented into the wall or ceiling. Thus the cables are firmly griped between the two halves
of the cleats and secured to the supporting wall or ceiling. The cleats used are of different
numbers of cables respectively. The cleats are of three types one groove, two grooves, three
grooves to accommodate one, two and three cables respectively.

Advantages

1) It is the cheapest system of internal wiring.

2) Its installation and dismantlement is easy and quick.

3) Inspection, alterations and additions can be easily made.

4) Little skill is required.

Disadvantages

1) It is not good looking.

2) It is quit temporary and perishes quickly.

3) The wires are exposed to mechanical injury.

4) Oil and smoke are injurious to VIR insulation.

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Fields of application.

The type of wiring is very suitable for temporary installations in dry places. This is
also acceptable where appearance is not so important and cheapness is the main
consideration. This system is not suitable for use in domestic premises.

2. Wooden Casing and Capping Wiring.

The cable used in this type of wiring is either VIR or PVC or any other approved
insulated cables. The cables are carried through the wooden casing enclosures. The casing
consists of V-shaped grooves (usually two to hold the cables of opposite polarities in
different grooves) and is covered at the top by means of rectangular strips of wood known
as capping of same width as that of casing. The capping is screwed to the casing by means
of wooden screws fixed at every 15cm on the centre fillet. Two or three cables of same
polarity ( either all phases or all neutrals ) may be run in one groove and in no case the
cables of opposite polarity should be run in the same groove. The casing is usually placed
3.2mm apart from wall or ceiling by means of porcelain distance pieces of thickness not less
than 6.5mm in order to keep the casing dry at the back.

3. CTS or TRS Wiring.

In this type of wiring the cables used may be single core, twin core or three core
TRS cables with a circular oval shape. Usually single core cables are preferred. TRS cables
are sufficiently chemical proof, water proof, steam proof but are slightly affected by
lubricating oils. TRS cables are run on well seasoned, perfectly straight and well varnished
teak wood batten of thickness 10mm at least. The width of the batten depends upon the
number and size of cables to be carried by it. The battens are available in width of 13, 19,
25, 31, 38, 44, 50, 56, 63, 69 and 75mm. The wooden battens are secured to the wall or
ceiling by flat head wooden screws to wood or other approved plugs at an interval not
exceeding 75cm. The cables are held on the wooden batten by means of tinned brass link
clips already fixed on the batten with brass pins and spaced at an interval of 10cm in case of
horizontal runs and 15cm in case of vertical runs.

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Advantages

1) Its installation is easy and quick.

2) Long life.

3) Within certain limit it is fire proof.

4) It can withstand the action of most chemicals such as acids and alkalis.

5) It is cheaper than other types of wiring except cleat wiring,

Disadvantages.

1) Good workmanship is required to make a sound job in TRS wiring.

2) This type of wiring cannot be recommended for use in situations open to sun or rain.

Fields of application.

The TRS wiring is suitable for low voltage installations and is extensively used for
lighting purposes everywhere ie, in domestic, commercial or industrial buildings except
workshop where it is liable to mechanical injury. This type of wiring is suitable in situations
where acids and alkalis are likely to be present.

4. Lead Sheathed Wiring.

This type of wiring employs conductors insulated with VIR and is covered with an
outer sheath of lead aluminium alloy containing about 95% lead. This metal sheath gives
protection to the cable from mechanical injury, dampness and atmospheric corrosion. The
whole lead covering is made electrically continuous and is connected to earth at the point of
entry to protect against electrolytic action due to leaking current and to provide safety
against the sheath becoming a live. The cables are run on wooden batten and fixed by
means of link clips as in TRS wiring.

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Advantages.

1) It provides protection against mechanical injury better than provided by TRS wiring

2) Its life is long if proper earth continuity is maintained throughout.

3) It can be used in situations exposed to rain and sun light.

Disadvantages.

1) It is costlier than TRS wiring.

2) It is not suitable for places where chemical corrosion may occur.

3) Skilled labour and proper supervision is required.

Fields of applications.

It may be used in places exposed to sun and rain provided no joint is exposed. It may
also be used in damp places with a suitable protective covering. This type of wiring is not very
common in use these days except for some small installations and distribution boards etc.

5. Conduit Wiring.

In this system of wiring PVC pipes known as conduits are installed on the surface of
walls by means of saddles or pipe hooks or buried under plaster and VIR or PVC cables are
drawn into afterwards by means of a GI wire of size of about 18SWG.

Advantages.

1) It provides protection against mechanical damage.

2) It provides complete protection against fire due to short circuits etc.

3) The whole system is water proof.

4) Long life

5) It is shock proof also if earth and bonding is properly done.

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Disadvantages.

1) It is very costly system of wiring.

2) Its erection is not so easy and requires time.

3) Experienced and highly skilled labour is required.

Fields of applications.

As this system of wiring provides protection against fire, mechanical damage and
dampness so this is the only approved system of wiring for textile mills, saw mills, flour
mills, lighting and motor wiring, records room, residential and public buildings where the
appearance is the prime thing.

CHOICE OF WIRING

The following factors should be considered before selecting a particular type of wiring.

1. Safety : The first and foremost consideration is safety to a person using electricity against
leakage or shock. Where there is a possibility of fire hazard conduit wiring is used.

2. Mechanical Protection : The wiring must be protected from mechanical damage during use.

3. Permanency : The wiring must not deteriorate unduly by action of weather. Fumes, dampness
etc.

4. Appearance : The wiring should he good looking.

5. Durability : The wiring must be durable.

6. Accessibility : In wiring system there should be facilities for extension, renewal or alterations.

7. Initial Cost : The wiring selected should suit the pocket of the owner of the building

8. Maintenance Cost : The wiring should have as far as possible the lowest maintenance cost.

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 Engineering Workshop Practice Manual

SOLDERING PRACTICE

SOLDERING

Soldering is defined as "the joining of metals by a fusion of alloys, which have relatively
low melting point”. In other words, you use a metal that has a low melting point to adhere the
surfaces to be soldered together. Soldering is more like gluing with molten metal than anything
else. Soldering is also a must have skill for all sorts of electrical and electronics work. It is also a
skill that can only be developed with practice.

SOLDERING EQUIPMENT

Soldering requires two main things: a soldering iron and solder. Soldering irons are the heat
source used to melt solder. Irons of the 15W to 30W range are good for most electronics/printed
circuit board work. Using anything higher in wattage and you risk damaging either the component
or the board. Note that you should not use so-called soldering guns. These are very high wattage
and generate most of their heat by passing an electrical current through a wire. Because of this, the
wire carries a stray voltage that could damage circuits and components. The choice of solder is also
important. One of the things to remember is to never use acid core solder. Acid core solder will
corrode component leads, board traces and form conductive paths between components. The best
solder for electronics work is a thin rosin core solder.

1. Remember that when soldering, the rosin in the solder releases fumes. These fumes are
harmful to your eyes and lungs. Therefore, always work in a well-ventilated area.

2. Hot solder is also dangerous. Be sure not to let it splash around, because it will burn you
almost instantly.

3. After you are done soldering, you must wash your hands thoroughly - since the solder
contains lead.

4. The fumes do not contain lead but contain solder flux which is still hazardous to your health
so avoid ingesting them.

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Exercise No.1 Date:

ONE LAMP CONTROLLED BY ONE SWITCH

Lamp
L L
20 cm

230V N
20 cm
AC Supply P
Supply 5A
Fuse
20 cm

S
S1
Switch
(1 way)

LAYOUT CIRCUIT DIAGRAM

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Exercise No.1 Date:

ONE LAMP CONTROLLED BY ONE SWITCH

Aim :

To wire up a circuit one lamp controlled by one switch in conduit wiring system.

Tools required:

Sl no Name of tool & Specification Quantity Remarks

1 Screw driver 200mm 1
2 Line tester 500V(neon) 1
3 Cutting pliers 150mm(insulated) 1
4 Combination pliers 150mm 1
5 Hammer(ball peen)225gm 1
6 Pocker150mm 1
7 Firmer chisel 25mm 1
8 Hack saw 300mm 1

Materials required:

Sl. Name of materials & Specifications Quantity Remarks

No.

Procedure:

1. Draw layout on the wiring board.

2. According to the layout, fix 20mm conduit on the board using saddles.
3. Draw cables through the conduit and connect as per connection diagram.
4. Fix lamp holder and switch on round block.
5. Give the specified supply and verify lamp status for different positions of switches.

Result :

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Exercise No.2 Date:

STAIR CASE WIRING

Lamp
L1 L1

15 cm

230V N
15 cm 15 cm 15 cm
AC Supply P
Supply 5A
Fuse
15 cm

15 cm

S1 S2
S1 S2
Switch Switch
(2 way) (2 way)

LAYOUT CIRCUIT DIAGRAM

STATUS TABLE

Sl.no. S1 S2 L1

1 OFF

2 ON

3 OFF

4 ON

S1 & S2 – Two way switches

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Exercise No.2 Date:

STAIR CASE WIRING

Aim
1. Prepare an estimate to carry out PVC Surface conduit wiring as per the given
layout, to control one lamp from two different places by two switches
independently.
2. Carry out wiring on the wiring board.

Tools required

Sl no Name of tool &specification Quantity Remarks

1 Screw driver 200mm 1
2 Line tester 500V(neon) 1
3 Cutting pliers 150mm(insulated) 1
4 Combination pliers 150mm 1
5 Hammer(ball peen)225gm 1
6 Pocker150mm 1
7 Firmer chisel 25mm 1
8 Hack saw 300mm 1

Materials required
Sl. Name of materials & specifications Quantity Remarks
No.

Procedure
1. Draw layout on the wiring board.
2. According to the layout, fix 20mm conduit on the board using saddles.
3. Draw cables through the conduit and connect as per connection diagram.
4. Fix lamp holder and switches on round blocks.
5. Give the specified supply and verify lamp status for different positions of switches.

Result :

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Exercise No.3 Date:

SINGLE PHASE MOTOR STARTER WIRING DIAGRAM

Normally Normally
Open Closed
Switch Switch

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Exercise No.3 Date:

SINGLE PHASE MOTOR STARTER WIRING DIAGRAM

Aim:-
To study the wiring diagram of a single phase motor with a DOL starter.

Tools required:

Sl No Name of tool &specification Quantity Remarks

1 Screw driver 200mm 1
2 Connector screw driver 150mm 1
3 Line tester 500V(neon) 1
4 Cutting pliers 150mm(insulated) 1
5 Combination pliers 150mm 1

Materials required

Sl.No. Name of materials & specifications Quantity Remarks

Procedure:-
1. Connections were made as per connection diagram.
2. Check the circuit for continuity.
3. Given the supply to the circuit after checking.
4. Finished the work neatly and correctly.

Result:-

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2022

Exercise No.4 Date:

SOLDERING & DE- SOLDERING

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 SOLDERING & DE- SOLDERING

Aim :
To practice soldering and de-soldering for the given electronic circuit using a
soldering iron.

Apparatus required:-

Sl no Name of tool &specification Quantity Remarks

1 Soldering iron (10W or 35W) 1No
2 Solder (60/40grade ) 1
3 Flux 1
4 Connecting wires 1
5 Lead 1
6 Nose plier 1

Procedure:-

1. Clean the terminals of LED and connecting wires.

2. Clean the tips of soldering iron before heating.
3. Heat the soldering iron and apply solder to the tip as soon as it is hot to melt on it.
4. Solder the connections using soldering iron tip at joints.
5. Trim excess component leads with side cutter.
6. Connect the supply and observe the result.
7. Dismantle the components using soldering iron and clean the components.

Result:-
 ELECTRICAL WIRING/SOLDERING
1. Name the safety devices used to protect the electric circuits from overload?
2. Differentiate between fuse and a circuit breaker
3. What are the safety precautions to be taken in an electrical workshop?
4. Name different wiring tools?
5. What are the different types of switches used?
6. What is soldering? What are the tools required for soldering operation?
7. How induction motors are classified for producing phase difference between two
windings?
8. What is the function of flux in soldering?
9. What is mean by wave soldering?
10. What are the different measuring instruments used in electrical workshop