Bitanhuan National High School

Baybay City Division Baybay

City, Leyte

11

Electrical
Installation
a nd
Maintenance
 Bitanhuan National High School
Baybay City Division Baybay City, Leyte

Quarter 2 - Week No. 2 Information Sheet No. 1

Subject : Electrical Installation and Maintenance

Grade Level : 11
Subject Type : Specialized
Prepared by : Ruel M. Telin-T1-MNHS
Learning Competency: Install Electrical Metallic Tubing
(TLE-IAE19-12RC-IIa-j-1)
Objectives : 1. Preparing metal conduit pipes for installation:
cutting by hacksaw;
2. Preparing metal conduit pipes for installation:
cutting by pipe cutter;
3. Assembling cutting threads using conduits stock
and dies; and
4. Joining rigid metal conduit to a non-screw thread
type box.

DEFINITION OF TERMS

Electrical Conduit system - is a raceway or piping system that protects wires and
cables from impact, moisture, and vapors. It is a path for either power or communication
(low voltage) electrical wiring. It is usually tubular and made of metal (galvanized steel,
stainless steel, aluminum) or non-metallic materials (plastics) and is either rigid or
flexible. Special types of conduit are required for wet areas and hazardous areas.
Rigid – is not pliant or flexible; hard: a rigid strip of metal. firmly fixed or set
Burr - a rough edge or ridge left on an object (especially of metal) by the action of a tool
or machine.
Locknut - a nut designed so that, once tightened, it cannot be accidentally loosened.
Bushing - a metal lining for a round hole, especially one in which an axle revolves Nipple
- is a short length of conduit or tubing material which is used to extend the system
Ratchet - is a mechanical device that allows continuous linear or rotary motion in only
one direction while preventing motion in the opposite direction.
Elbows - are bent sections of conduit or tubing used to change raceway direction or
bypass obstructions
BSP - British Standard Pipe
DIN - German Industrial Norm ISO
- International Organization for
Standardization.
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Baybay City Division Baybay City, Leyte

KEY CONCEPTS

A conduit system can be made waterproof or submersible. Metal conduit can be used to
shield sensitive circuits from electromagnetic interference, and also can prevent emission
of such interference from enclosed power cables. Non-metallic conduits resist corrosion
and are light-weight, reducing installation labor cost.

When installed with proper sealing fittings, a conduit will not permit the flow of
flammable gases and vapors, which provides protection from fire and explosion hazard in
areas handling volatile substances.

Both metal and plastic conduit can be bent at the job site to allow a neat installation
without excessive numbers of manufactured fittings. This is particularly advantageous
when following irregular or curved building profiles. Special tube bending equipment is
used to bend the conduit without kinking or denting it.

The cost of conduit installation is higher than other wiring methods due to the cost of
materials and labor. In applications such as residential construction, the high degree of
physical damage protection may not be required, so the expense of conduit is not
warranted. Conductors installed within conduit cannot dissipate heat as readily as those
installed in open wiring, so the current capacity of each conductor must be reduced if
many are installed in one conduit. It is impractical, and prohibited by wiring regulations,
to have more than 360 degrees of total bends in a run of conduit, so special outlet
fittings must be provided to allow conductors to be installed without damage in such
runs.

1. Preparing Metal Conduit Pipes for Installation: Cutting by Hacksaw

Once the pipe is inserted and tightened. Before

you cut any conduit pipes, make sure you have
measured and marked the correct length
exactly. (Fig.1)

Fig.1

Check that the blade is lightly tightened in the frame

and that the teeth point forward. Take up the
hacksaw and position yourself as shown here, with
yourself shoulder pointing in the direction you
intend to cut. Note the position of the feet, which
allows free and controlled movement of the body
when cutting. (Fig. 2)

Fig. 2
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Place; the left hand on the pipe, close to the cutting

line with the thumb against the saw blade. When the
first cuts have been made move the left hand to the
top front curve of the frame and use both hands for
the cutting operation. (Fig. 3)

Fig. 3

When sawing, use the full length of the blade,

gradually increasing pressure on the forward
stroke and releasing the pressure as the
blade is drawn back. (Fig. 4)

Fig. 4

Before finishing the cutting operation, the

pipe must be supported with the left hand.
This will prevent the blade of the hacksaw
being damaged. (Fig. 5)

Fig. 5

Smooth off the cut pipe and deburr by filing

outside and inside. File square by using a
rough flat file or a half round file. (Fig. 6)
Check that the ends of the cut pipe are
square and free from burrs. (Fig. 7)

Fig. 6 Fig. 7

When assembling and installing conduit pipes in

new or existing electrical systems, all pipe work
must be finished accurately and be free from any
burrs in the inside of the pipe. (Fig. 8)
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Fig. 8

2. Preparing Metal Conduit Pipes for Installation: Cutting by Pipe

Cutter
The cutter consists of: (Fig. 9)

a. Cutting Wheel
b. Rollers
c. Jacking Screw (Feeding Screw)

Fig. 9

Since cutting the pipe in this manner leaves a

large ridge on the inside of the pipe which would
obstruct the conductors to be installed. The
pipe must be deburred or reamed with a file or a
pipe reamer. (Fig.10)

Fig. 10

Pipes to be cut must be held steady and

prevented from falling by holding
them in suitable vise. (Fig.11)

Fig. 11

Chain pipe vises are made to hold pipes with

an outside diameter of up to 8"or 200 mm.
They are mounted on solid benches. (Fig.12)

Fig.12

Open the vise and insert the pipe so it is

horizontal and parallel to the jaw serrations. (Fig.
13)
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Baybay City Division Baybay City, Leyte

Fig. 13

Before you cut any, make sure you have

measured and marked the correct length
exactly. (Fig.14)

Fig.14

Rotate the pipe cutter around the

pipe. (Fig.15)

Fig.15

After one or two turns, check that the

cutting wheel is sitting exactly on the
scribed line. (Fig.16)

Fig. 16

Keep rotating the pipe cutter around the

pipe. (Fig.17)

Fig.17

After two or three more turns, use the

jacking screw to put pressure on
the cutting wheel. (Fig.18)

Fig.18
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Before the cut is completed support the

pipe with your left hand so that it does not
fall. (Fig.19)

Fig.19

Use the jacking screw to put more pressure

on the cutting wheel until the pipe is cut
through. (Fig.20)

Fig. 20

If the pipe is not square and free from burrs, file

square by using a
rough flat file or a half round file. (Fig.21)

Fig. 21

Another way to remove burrs inside the pipe

is by means or reamer. The vise will hold the
pipe steady during
the reaming process. (Fig.22)

Fig. 22

3. Cutting Thread Using Conduit Stock and Dies

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Take note:

1. Full conduit pipe lengths are approximately: 3.00 meters or 10 ft.

2. All fittings made for use on conduit pipe for water supply are screwed to British
Standard Gauge (BSP) and the female outlets of all pipe fittings have a parallel pipe
thread.

Conduit pipe joint: (Fig.23)

(1) Parallel Female Thread
(2) Tapered Male Thread
(3) Hemp

Fig. 23

Hemp packing is used to ensure that any

small space between two metal
threads (Male and Female threads)
is filled. (Fig. 24)
Fig. 24

Examine carefully any stock and set of

dies you are going to use. Find out the
purpose of each part. There are many
varieties of stocks and dies.
(Fig.25)

Fig.25

Different types of Pipe Cutter

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A. Stock and dies ratchet-type with one handle. (Fig. 26)

Open the adjustment lever and insert the

four (4) dies into the numbered openings.

Check that the dies sit in the correct

position.

Close the adjustment lever and check

that the right cutting pipe diameter is
set.

Fig. 26
When changing dies be sure that the number on the top edge of the die corresponds with
the number of the slot into which it is to be placed.

Most dies can be set to cut the thread a little oversize or undersize. This is done by
setting the adjustment lever a little in front of or a little behind the pipe diameter line.

B. Drop Head Stock and Dies

Select the correct die head for threading the

pipe. (Fig. 27)

Fig. 27

Pull the knob or wheel and set the die head in

the ratchet stock. (Fig. 28)

Fig. 28

Check that the die head sits in the correct

position. (Fig. 29)

Fig. 29
C. Stock and Dies, ratchet-type, with two handles
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Baybay City Division Baybay City, Leyte

Open the adjustment lever and insert the four

(4) dies into the numbered openings. (Fig. 30)

Check that the dies sit in the correct position.

Close the adjustment lever and check that the

right cutting pipe diameter is set. Fig. 30

When changing dies be sure that the number on the top edge of the die corresponds with
the number of the slot into which it Is to be placed.

Most dies can be set to cut the thread a little

oversize or undersize. (Fig. 31)

This is done by setting the adjustment lever a

little in front of or a little behind the pipe
diameter line.

Fig. 31

Adjust the pipe guide for correct

sliding, fit and lock into position. (Fig. 32)

NOTE:
Drop head stock and dies have a
fixed pipe guide and no adjustment Is
necessary.
Fig. 32

Apply a cutting lubricant to the part

which is to be threaded. (Fig. 33)

NOTE:
Use lard oil or mineral lard oil when
threading conduit pipes. Fig. 33
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Rotate the handle clockwise with slight

pressure towards the pipe, at right angles to
the pipe axis.

When the dies bite into the pipe, stop

pushing and simply continue the
Fig. 34
rotation, by moving the handle up
and down. (Fig. 34)

If the stock and dies stick, you probably have

some metal chips. In the way, in which case
you must ease the handle back anti-
clockwise. This breaks off long cuttings and
clears the cutting edges of the dies. (Fig. 35)

(1) Reverse the knob or wheel

Fig. 35

The length of a pipe thread should be between 15 mm and 36 mm (A) long –

depending on the pipe diameter.

(Fig. 36)
Fig. 36

When you have cut the desired length of

thread, reverse the ratchet knob, ease the
handle and turn the stock anti-clockwise until
you can
take the stock and dies off the

threaded pipe. (Fig. 37) Fig. 37

After

threading and cleaning the pipe thread, screw

the fitting onto the pipe end by hand and test
the cut thread.
(Fig. 38) Fig. 38
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The length of thread should be sufficient to fit half-

way into the
socket or coupling and fully into other
fittings. (Fig. 39) Fig. 39

After threading the conduit pipe, clean the

stock and dies by wiping the metal parts
with .an oily piece of
cloth. (Fig. 40) fig. 40

Store the stocks and dies in the protective

carrying case.

4. Joining Rigid Metal

Conduit to a Non-screw
Thread Type Box

Rigid conduit fittings are

accessories such as
lockouts, bushings,
coupling, adaptors,
condulets, nipples and
boxes. These boxes do in
a non-screw thread or
screw-thread types.

The bushing and lockout are used for connecting rigid metal conduit with
screw thread to a non-screw thread box. Their sizes depend upon the sizes of
the conduits. The figure at
the right shows the bushing and locknut. (Fig. 41)
(a) bushing
(b) locknut

Fig. 41
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The non-screw-thread electrical boxes

are used on ceiling outlet box, junction
box, and switch box or as a
convenience outlet box. The figure
shows the different kinds of boxes
used in an electrical installation.
(Fig.42)
(a) Ceiling Outlet Box
(b) Junction Box
(c) Switch and Convenience outlets
(d) Cut-Out Box

Fig. 42

Knock the machine-cut portion of the box of

the box using a screwdriver as shown in figure.
Each removable part is partially machined cut
to make its
removal easy when necessary. (Fig. 43)

Fig. 43

Insert the end of the conduit into the

knocked-out hole of the electrical box.
(Fig. 44)

Fig.44

Before joining the conduit to a box or other

fitting, be sure to remove the sharp edges
(burrs) at its ends by filing. These sharp
edges can injure
insulation of conductors when pulling
them into the conduit and can cause
Fig. 45 grounded or shorted circuits. (fig. 45)
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Screw on the bushing clockwise at

one end of the rigid conduit. (Fig. 46)

Fig. 46

Join the threaded-rigid metal conduit to the

non-screw thread type box by using coupler
and internal bushing. (Fig. 47)

Fig. 47

Place the end of the coupler against the

hole of the electrical box. Then screw-on
the internal bushing (male bush). (Fig.
48)

Fig. 48

Hold the conduit steadily while turning the

internal bushing clockwise. Continue
turning it until the joint is tight enough.
(Fig. 49)

Fig. 49
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Reference Materials:

Institute of Integrated Electrical Engineers. PHILIPPINE ELECTRICAL

CODE, PART 1 2000 Edition. June 2002. Bookman Inc.,

Technical Education and Skills Development Authority

East Service Road, South Superhighway, Taguig, Metro Manila

https://www.google.com
 Bitanhuan National High School
Baybay City Division Baybay City, Leyte

- Week No.2

Quarter 2 Activity No. 1

Name: _____________________________________Gr & Sec.: _______________ Score: _____

Subject : Electrical Installation and Maintenance

Grade Level : 11
Subject Type : Specialized
Prepared by : Ruel M. Telin-T1-MNHS
Learning Competency: Install Electrical Metallic Tubing
(TLE-IAE19-12RC-IIa-j-1)
Objectives : Preparing metal conduit pipes for installation:
cutting by hacksaw

Directions:

A. True or False. Write T if the statement is correct, if not write F on

your answer sheet.

___ 1. Before cutting any conduit pipes, make sure to measure and mark the correct
length exactly.

___ 2. Shoulder should be pointing in the direction you intend to cut.

___ 3. When sawing, use the half length of the blade.

___ 4. Before finishing the cutting operation, the pipe must be supported with the left
hand to prevent the blade of the hacksaw being damaged.

___ 5. To smooth off the cut pipe and deburr you have to wipe out with white clean cloth.

B. Essay. What is Electrical Conduit System? (10 pts.) Write your

answer on your answer sheet.
 Bitanhuan National High School
Baybay City Division Baybay City, Leyte

- Week No.2
 Bitanhuan National High School
Baybay City Division Baybay City, Leyte

- Week No.2

Quarter 2 Activity No. 2

Name: _____________________________________Gr & Sec.: _______________ Score: _____

Subject : Electrical Installation and Maintenance

Grade Level : 11
Subject Type : Specialized
Prepared by : Ruel M. Telin-T1-MNHS
Learning Competency: Install Electrical Metallic Tubing
(TLE-IAE19-12RC-IIa-j-1)
Objectives : Preparing metal conduit pipes for installation: cutting
by pipe cutter

Directions:
A. Identify the parts according to its number. Write your answer on your answer sheet.

1. ______________________

2. ______________________

3. ______________________

4. ______________________ 5 4

5. ______________________

6. ______________________
6
7
7. ______________________

8. ______________________

9. ______________________
8

10

10. _____________________
 Bitanhuan National High School
Baybay City Division Baybay City, Leyte

- Week No.2

Quarter 2 Activity No. 3

Name: _____________________________________Gr & Sec.: _______________ Score: _____

Subject : Electrical Installation and Maintenance

Grade Level : 11
Subject Type : Specialized
Prepared by : Ruel M. Telin-T1-MNHS
Learning Competency: Install Electrical Metallic Tubing
(TLE-IAE19-12RC-IIa-j-1)
Objectives : Assembling cutting threads using conduits stocks and
dies
Direction: Match column A with column B. Write the letter of your answer on your answer
sheet.
Column A Column B

___ 1. Full conduit pipe length. A. British Standard Gauge

___ 2. It is used to ensure that any small thread is filled. B. Ratchet

___ 3. It is a mechanical device that allows continuous C. 24mm and 36mm

Linear motion in only one direction while preventing
Motion in the opposite direction. D. Adjustment Lever

___ 4. All fittings made for use on conduit pipe are screwed E. 10 ft.
According to ____.
F. Lubricant
___ 5. In a stock and dies, there are ____ dies to be set
in the correct position. G. Hemp packing

___ 6. _____ will be set to cut the thread a little oversize H. Drop Head
or undersize.

___ 7. In ___________ stock and dies have a fixed pipe guide I. 15mm and 36mm
and no adjustment is necessary.

___ 8. Apply a cutting _________ to the part which is to J. 12 ft.

Threaded.

___ 9-10. The length of a pipe thread should be between K. 4

Between _____ and ______ long depending on the
Pipe diameter.
 Bitanhuan National High School
Baybay City Division Baybay City, Leyte

- Week No.2

Quarter 2 Activity No. 4

Name: _____________________________________Gr & Sec.: _______________ Score: _____

Subject : Electrical Installation and Maintenance

Grade Level : 11
Subject Type : Specialized
Prepared by : Ruel M. Telin-T1-MNHS
Learning Competency: Install Electrical Metallic Tubing
(TLE-IAE19-12RC-IIa-j-1)
Objectives : Joining rigid metal conduit to a non-screw thread type
box.

Direction: Fill in the blanks. Write the correct word or words on the blank to make the
statement complete.

A. Rigid conduit fittings are accessories such as 1. ________________, 2. _______________,

3. ____________________, 4. ___________________, 5. ___________________, 6. ___________,

7. ____________________.

B. The non-screw-thread electrical boxes are used on 8. _______________________,

9. _____________________________ and 10. ____________________________.

C. Join the threaded-rigid metal conduit to the non-screw thread type box by

using 11. ______________________ and 12. ___________________________.

D. Before joining the conduit to a box or other fitting, be sure to remove the
13. _____________________ at its ends by filing. These sharp edges can
injure insulation of conductors when pulling them into the conduit and
can cause

14. _______________________ or 15. ______________________________.