Wireman

NSQF LEVEL - 4

1st Year

TRADE PRACTICAL

SECTOR: POWER

DIRECTORATE GENERAL OF TRAINING

MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
GOVERNMENT OF INDIA

NATIONAL INSTRUCTIONAL
MEDIA INSTITUTE, CHENNAI
Post Box No. 3142, CTI Campus, Guindy, Chennai - 600 032
(i)
Sector : Power
Duration : 2 - Years
Trades : Wireman - 1st Year Trade Practical - NSQF Level - 4

Developed & Published by

National Instructional Media Institute

Post Box No.3142
Guindy, Chennai - 600 032
INDIA
Email: chennai-nimi@nic.in
Website: www.nimi.gov.in

Copyright © 2021 National Instructional Media Institute, Chennai

First Edition :August 2021 Copies:500

Rs.355/-

(ii)
 FOREWORD

The Government of India has set an ambitious target of imparting skills to 30 crores people, one out of every
four Indians, by 2020 to help them secure jobs as part of the National Skills Development Policy. Industrial
Training Institutes (ITIs) play a vital role in this process especially in terms of providing skilled manpower.
Keeping this in mind, and for providing the current industry relevant skill training to Trainees, ITI syllabus
has been recently updated with the help of Media Development Committee members of various stakeholders
viz. Industries, Entrepreneurs, Academicians and representatives from ITIs.

The National Instructional Media Institute (NIMI), Chennai, has now come up with instructional
material to suit the revised curriculum for Wireman Trade Practical 1st Year in Power Sector under
Yearly Pattern. The NSQF Level - 4 Trade Practical will help the trainees to get an international equivalency
standard where their skill proficiency and competency will be duly recognized across the globe and this will
also increase the scope of recognition of prior learning. NSQF Level - 4 trainees will also get the opportunities
to promote life long learning and skill development. I have no doubt that with NSQF Level - 4 the trainers and
trainees of ITIs, and all stakeholders will derive maximum benefits from these Instructional Media Packages
IMPs and that NIMI's effort will go a long way in improving the quality of Vocational training in the country.

The Executive Director & Staff of NIMI and members of Media Development Committee deserve appreciation
for their contribution in bringing out this publication.

Jai Hind

Director General
Directorate General of Training
Ministry of Skill Development & Entrepreneruship
Government of India.

New Delhi - 110 001

(iii)
 PREFACE
The National Instructional Media Institute (NIMI) was established in 1986 at Chennai by then Directorate
General of Employment and Training (D.G.E & T), Ministry of Labour and Employment, (now under Directorate
General of Training, Ministry of Skill Development and Entrepreneurship) Government of India, with technical
assistance from the Govt. of Federal Republic of Germany. The prime objective of this Institute is to develop
and provide instructional materials for various trades as per the prescribed syllabi under the Craftsman and
Apprenticeship Training Schemes.

The instructional materials are created keeping in mind, the main objective of Vocational Training under
NCVT/NAC in India, which is to help an individual to master skills to do a job. The instructional materials are
generated in the form of Instructional Media Packages (IMPs). An IMP consists of Theory book, Practical
book, Test and Assignment book, Instructor Guide, Audio Visual Aid (Wall charts and Transparencies) and
other support materials.

The trade practical book consists of series of exercises to be completed by the trainees in the workshop.
These exercises are designed to ensure that all the skills in the prescribed syllabus are covered. The trade
theory book provides related theoretical knowledge required to enable the trainee to do a job. The test and
assignments will enable the instructor to give assignments for the evaluation of the performance of a trainee.
The wall charts and transparencies are unique, as they not only help the instructor to effectively present a
topic but also help him to assess the trainee's understanding. The instructor guide enables the instructor to
plan his schedule of instruction, plan the raw material requirements, day to day lessons and demonstrations.

IMPs also deals with the complex skills required to be developed for effective team work. Necessary care
has also been taken to include important skill areas of allied trades as prescribed in the syllabus.

The availability of a complete Instructional Media Package in an institute helps both the trainer and
management to impart effective training.

The IMPs are the outcome of collective efforts of the staff members of NIMI and the members of the Media
Development Committees specially drawn from Public and Private sector industries, various training institutes
under the Directorate General of Training (DGT), Government and Private ITIs.

NIMI would like to take this opportunity to convey sincere thanks to the Directors of Employment & Training
of various State Governments, Training Departments of Industries both in the Public and Private sectors,
Officers of DGT and DGT field institutes, proof readers, individual media developers and coordinators, but for
whose active support NIMI would not have been able to bring out this materials.

R. P. DHINGRA
Chennai - 600 032 EXECUTIVE DIRECTOR

(iv)
 ACKNOWLEDGEMENT

National Instructional Media Institute (NIMI) sincerely acknowledges with thanks for the co-operation and contribution
extended by the following Media Developers and their sponsoring organisation to bring out this IMP for the trade of
Wireman 1st Year Trade Practical - NSQF LEVEL - 4 under the Power Sector for ITIs.

MEDIA DEVELOPMENT COMMITTEE MEMBERS

Smt. S. Nirmala _ ATO, (F.D.T)

Govt. ITI, Vaniyambadi.

Smt. D. Kalaivani _ Contract Faculty (F.D.T)

Govt. ITI (W) Dindigul.

NIMI - COORDINATORS

Shri. Nirmalya Nath - Deputy Director,

NIMI, Chennai - 32.

Shri. Subhankar Bhowmick - Assistant Manager

NIMI, Chennai - 32.

Shri. V. Gopalakrishnan - Assistant Manager

NIMI, Chennai - 32.

NIMI records its appreciation of the Data Entry, CAD, DTP Operators for their excellent and devoted services in
the process of development of this Instructional Material.
NIMI also acknowledges with thanks, the invaluable efforts rendered by all other staff who have contributed for the
development of this Instructional Material.
NIMI is grateful to all others who have directly or indirectly helped in developing this IMP.

(v)
 INTRODUCTION
TRADE PRACTICAL

The trade practical manual is intented to be used in workshop . It consists of a series of practical exercises
to be completed by the trainees during the one year course of the Wireman Trade supplemented and
supported by instructions/ informations to assist in performing the exercises. These exercises are designed
to ensure that all the skills in compliance with NSQF LEVEL - 4
The manual is divided into Seventeen modules.
Module 1 - Safety Practice
Module 2 - Hand Tools - Wire Joints - Soldering
Module 3 - Basic Electrical Practice
Module 4 - Pattern & Quality of Production
Module 5 - Cells and Batteries
Module 6 - Basic Workshop Practice
Module 7 - Magnetism and Capacitors - AC Circuits
Module 8 - Earthing
Module 9 - Basic Electronics
Module 10 - Measuring Instruments
Module 11 - Domestic Wiring Practice - I
Module 12 - Domestic Wiring Practice - II
Module 13 - Illumination
Module 14 - Industrial Wiring - I
Module 15 - Commercial Wiring
Module 16 - Industrial Wiring - II
Module 17 - Computer Awareness

The skill training in the shop floor is planned through a series of practical exercises centred around ome
practical project. However, there are few instances where the individual exercise does not form a part of
project.
While developing the practical manual a sincere effort was made to prepare each exercise which will be easy
to understand and carry out even by below average trainee. However the development team accept that there
is a scope for further improvement. NIMI, looks forward to the suggestions from the experienced training
faculty for improving the manual.
TRADE THEORY
The manual of trade theory consists of theoretical information for the one year course of the Wireman Trade.
The contents are sequenced according to the practical exercise contained in the manual on Trade practical.
Attempt has been made to relate the theoretical aspects with the skill covered in each exercise to the extent
possible. This co-relation is maintained to help the trainees to develop the perceptional capabilities for
performing the skills.
The Trade theory has to be taught and learnt along with the corresponding exercise contained in the manual
on trade practical. The indicating about the corresponding practical exercise are given in every sheet of this
manual.
It will be preferable to teach/learn the trade theory connected to each exercise atleast one class before
performing the related skills in the shop floor. The trade theory is to be treated as an integrated part of each
exercise.
The material is not the purpose of self learning and should be considered as supplementary to class room
instruction.

(vi)
 CONTENTS

Exercise No. Title of the Exercise Learning Page No.

Outcome

Module 1 : Safety Practice

1.1.01 Practice on implementation of various sagety measures in the
shop floor 1
1.1.02 Visit to the different sections of the Institute and draw the layout 3
1.1.03 Demonstration on elementary first aid. Artificial Respiration 5
1.1.04 Practice on use of fire extinguishers 1 9
1.1.05 Practice on occupational Safety and Health Importance of house
keeping and good shop floor practices 12
1.1.06 Interpret Health, Safety and Environment guidelines, legislations
and regulations as applicable. Disposal procedure of waste
materials like cotton waste, metal chips/burrs etc 14
1.1.07 Practice on use of Personal Protective Equipment (PPE), Follow the
prevention procedure for basic injury and basic first aid, Identify,
different hazards and avoidance and identify use safety signs for
personal safety measure 17
1.1.08 Preventive measures for electrical accidents and steps to be taken
in such accidents 24

Module 2 : Hand Tools - Wire Joints - Soldering

1.2.09 Demonstration of Trade hand tools 26
1.2.10 Identification of simple types- screws, nuts and bolts, chassis,
clamps, rivets etc 27
1.2.11 Use, care and maintenance of various hand tools. Familiarization
1
with signs and symbols of Electrical accessories 29
1.2.12 Practice in using cutting pliers, screw drivers etc. skinning the
cables, and joint practice on single strand 37
1.2.13 Demonstration and Practice on bare conductors joints--such as
rat tail, Britannia, straight, Tee, Western union Joints 40
1.2.14 Practice in soldering and brazing 43
1.2.15 Application of Wheatstone bridge in measurement of resistance and
determine the specific resistance 47
Module 3 : Basic Electrical Practice
1.3.16 Demonstration and identification of types of cables 50
1.3.17 Demonstration and practice on using standard wire gauge and
micrometer 51
1.3.18 Practice on crimping thimbles, Lugs 53
1.3.19 Examination and checking of cables and conductors and verification
of materials according to the span 2 56
1.3.20 Verification of Ohm’s Law 58
1.3.21 Verification of Kirchhoff’s Laws 60
1.3.22 Verification of laws of series and parallel circuits 63
1.3.23 Verification of open circuit and closed circuit network 66
1.3.24 Measuring unknown resistance using Wheatstone bridge, voltage
drop method 69

(vii)
Exercise No. Title of the Exercise Learning Page No.
Outcome

1.3.25 Experiment to demonstrate the variation of resistance of a metal with

the change in temperature 70
Module 4 : Basic Wiring Practice
1.4.26 Practice on installation and overhauling common electrical
accessories as per simple Electrical circuit / Layout 3 72
1.4.27 Fixing of switches, holder plugs etc. in T.W. boards 78
1.4.28 Identification and use of wiring accessories concept of switching 80
Module 5 : Cells and Batteries
1.5.29 Assembly of Dry cell- Electrodes-Electrolytes 84
1.5.30 Practice on Grouping of Dry cells for a specified voltage and current,
Ni cadmium and Lithium cell 85
1.5.31 Practice on Battery Charging, preparation of battery charging 88
4
1.5.32 Testing of cells, Installation of batteries, Charging of batteries by
different methods 90
1.5.33 Practice on Electroplating and anodizing, Cathodic protection 93
1.5.34 Routine, care and maintenance of Batteries 94
1.5.35 Charging of a Lead acid cell, filling of electrolytes- Testing of
charging checking of discharged and fully charged battery 96
Module 6 : Basic Workshop Practice
1.6.36 Marking use of chisels and hacksaw on flats, sheet metal filing
practice, filing true to line 98
1.6.37 Sawing and planning practice. Practice in using firmer chisel and
preparing simple half lap joint 101
1.6.38 Drilling practice in hand drilling and power drilling machines.
Grinding of drill bits 5 105
1.6.39 Practice in using taps & dies, threading hexagonal and square nuts
etc 109
1.6.40 Cutting external threads on stud and on pipes, riveting practice 113
1.6.41 Practice in using snips, marking and cutting of straight and curved
pieces in sheet metals 117
1.6.42 Bending the edges of sheets metals 119
1.6.43 Riveting practice in sheet metal. Practice in making different joints
in sheet metal in soldering the joints 120
Module 7 : Magnetism and Capacitors - AC Circuits

1.7.44 Trace the magnetic field 122

1.7.45 Assembly / winding of a simple electro magnet 123
1.7.46 Use of magnetic compass 125
1.7.47 Identification of different types of Capacitors 126
1.7.48 Charging and discharging of capacitor 6 128
1.7.49 Testing of Capacitors using DC voltage and lamp 130
1.7.50 Determine the characteristics of RL, RC and RLC in A.C. Circuits
both in series and parallel 131
1.7.51 Verify the relationship between Line and Phase values in 3 phase
star and delta connections 138

(viii)
Exercise No. Title of the Exercise Learning Page No.
Outcome

1.7.52 Measure the current, voltage, power and power factor in single and
poly- phase circuits 140
1.7.53 Measurement of energy in single and poly-phase circuits 142

1.7.54 Use of phase sequence meter 145

Module 8 : Earthing
1.8.55 Practice on Earthing – different methods of earthing 146
7
1.8.56 Measurement of Earth resistance by earth tester 149
1.8.57 Testing of Earth Leakage by ELCB and relay 151

Module 9 : Basic Electronics

1.9.58 Determine the resistance by Colour coding 152
1.9.59 Identification of active and passive electronic components 8 155
1.9.60 Interpret and the diodes symbol - Test construct and test half
wave rectifier circuit 160
1.9.61 Construct and test full wave rectifier ckt and bridge rectifier ckt 162
Module 10 : Measuring Instruments
1.10.62 Measurement of voltage, current and resistance in different circuits 165
1.10.63 Measurement of electrical power and energy by direct and indirect 171
1.10.64 Calibration of energy meters` 175
1.10.65 Measurement of current and voltage using CT and PT, Measurement
of 3 Phase energy using CT and PT. Phase sequence meter,
measure current and voltage using Tong tester 8 178
1.10.66 Power measurement by Two and Three watt meter method Insulation
resistance test by Megger 184
1.10.67 Measurement of earth resistance by earth tester 188
1.10.68 Calibration of indicating type analogue instruments: voltmeter,
ammeter, and wattmeter. Measurement of soil conductivity.
Introduction of Digital meters 190
Module 11 : Domestic Wiring Practice - I
1.11.69 Demonstration and Practice on connecting common electrical
accessories in circuits and testing them in series board 194
1.11.70 Demonstration on Testing and replacement of different types of fuses 197
1.11.71 Identification of different wiring materials and their specifications 199
1.11.72 Removing of insulation from assorted wires and cables 203
1.11.73 Demonstration and practice crimping thimbles/lugs of various sizes 207
9
1.11.74 Practice on jointing with single and multi-stranded conductors of
different wires and cables 210
1.11.75 Practice on marking layout on wiring boards 213
1.11.76 Practice in P.V.C. insulated cable wiring on wood battern with
distribution board and number of points 214
1.11.77 Practice of wiring: A) One lamp controlled by one SP switch, (B) Two
lamps controlled by two independent switches, (C) One lamp controlled
by two 2way switches (Staircase wiring), (D) One lamp controlled by
intermediate switch from three different locations, (E) Hospital wiring,
(F) Tunnel/ Godown wiring, (G) Hostel wiring, (H) Bell Buzzer
Indicator wiring, (I) Domestic wiring practice 216

(ix)
Exercise No. Title of the Exercise Learning Page No.
Outcome

Module 12 : Domestic Wiring Practice - II

1.12.78 Demonstration and practice of using Row tools 224
1.12.79 Demonstration and practice of casing and capping wiring 226
1.12.80 Testing of wiring installation by using Megger 228
1.12.81 Demonstration and practice in cutting and threading conduit pipes 9 234
1.12.82 Cold and hot bending of pipes 238
1.12.83 Fitting of conduit accessories 242
1.12.84 Preparation of conduit threads using different fittings and use of
running threads wiring in conduit, using metal clad 3 pin plug,
Earthing the conduit using earth clips and earth wire 244
Module 13 : Illumination
1.13.85 Installation of - Neon Sign tube, Mercury vapour (H.P. & L.P.),
Sodium vapour, Halogen Lamps, single tube, double tube, Metal
halide lamps. Emergency light 10 248
1.13.86 Practice on decoration lighting 255
1.13.87 Practice on using LUX Meter 257
1.13.88 Installation and testing of CFL Lamps and LED Lamps 258
Module 14 : Industrial Wiring - I
1.14.89 Practice usage of application and type insulating materials 260
1.14.90 Measurement of insulation resistance, of commercial and industrial 11
installation Additional practice in conduit wiring 261
1.14.91 Industrial power wiring involving single phase and 3phase motors
with switches and starters 264
Module 15 : Commercial Wiring
1.15.92 Inverter wiring./ Control panel wiring / multi-storeyed building wiring 267
1.15.93 Introduction to LAN (Local Area Network) wiring 272
1.15.94 Installation of single phase and 3 phase on line / off line UPS wiring 12 273
1.15.95 Testing of Industrial wiring and UPS wiring installation 276
1.15.96 Straight and cross crimping of RJ-45 cable 279
1.15.97 Crimping of co-axial cable, proper installation of co-axial cable from
dish antenna to Television set 283
Module 16 : Industrial Wiring - II
1.16.98 Installations Industrial wiring for mixed load, both light and power 285
1.16.99 Layout of L.V. AC/DC machines and their panels 287
1.16.100 Wiring of Low power A.C./ D.C. machines in metal conduit system
as per I.E. Rules 13 288
1.16.101 Testing of 3 phase power wiring installation 290
1.16.102 Wiring of different circuit using Single core cable use for 2 ways,
intermediate master switches etc 291
1.16.103 Testing of wiring installation 293
Module 17 : Computer Awareness
1.17.104 Identification of Computer Parts, Switching ON/OFF of PC, Safety
Precautions 14 297
1.17.105 Identifying and using Windows, like folders, files, Editing and saving 302
1.17.106 Windows Explorer, Notepad, Paint and calculator 312

(x)
Exercise No. Title of the Exercise Learning Page No.
Outcome

1.17.107&108 Windows, explorer, Notepad, Paint and Calculator 314

1.17.109 Internet Practicing – Browsing/Creating Email, Downloading 332

LEARNING / ASSESSABLE OUTCOME

On completion of this book you shall be able to
S.No. Learning Outcome Ref. Ex.No.

1 Make good quality electrical wire joints for single and multi strand conductors
suitable for applications with soldering following electrical safety precautions. 1.1.01 - 1.2.15
2 Draw and set up DC and AC circuits including R-L-C circuits with accurate
measurement of voltage, current, resistance, power, power factor and energy using
ammeter, voltmeter, ohm-meter, watt-meter, energy meter, power factor meter and
phase sequence tester with proper care and safety. 1.3.16 - 1.3.25
3 Plan, draw, estimate material, wire up and test different type of domestic wiring
circuits as per Indian Electricity rules and taking care of quality. Construction and
working of MCB & ELCB. Test a domestic wiring installation using Megger. 1.4.26 - 1.4.28
4 Identify the type of batteries, construction, working and application of Ni-cadmium,
lithium cell, lead acid cell etc. Demonstrate their charging and discharging, choosing
appropriate method and carryout the installation and routine maintenance with
due care and safety. 1.5.29- 1.5.35
5 Make choices to carry out basic jobs of marking out the components for filing,
drilling, and riveting, fitting and assembled using different components independently. 1.6.36 - 1.6.43
6 Draw and set up DC and AC circuits including R-L-C circuits with accurate
measurement of voltage, current, resistance, power, power factor and energy using
ammeter, voltmeter, ohm-meter, watt-meter, energy meter, power factor meter and
phase sequence tester with proper care and safety. 1.7.44 - 1.7.54
7 Plan and install Pipe & Plate earthing. Measure earth resistance by earth tester. 1.8.55 - 1.8.57
8 Select and perform electrical/ electronic measurements with appropriate instrument. 1.9.58 - 1.10.68
9 Plan, draw, estimate material, wire up and test different type of domestic wiring
circuits as per Indian Electricity rules and taking care of quality. Construction and
working of MCB & ELCB. Test a domestic wiring installation using Megger. 1.11.69 - 1.12.84
10 Plan and execute electrical illumination system viz. FL tube, HPMV lamp,
HPSV lamp, Halogen & metal halide lamp, CFL, LED lamp etc. 1.13.85 - 1.13.88
11 Plan, draw, estimate material, wire up and test different type of industrial wiring
circuits as per Indian Electricity rules and taking care of quality. 1.14.89 - 1.14.91
12 Plan, draw, estimate material, wire up and test different type of commercial and
computer networking wiring circuits as per Indian Electricity rules and taking care
of quality. 1.15.92 - 1.15.97
13 Plan, draw, estimate material, wire up and test different type of industrial wiring
circuits as per Indian Electricity rules and taking care of quality. 1.16.98 - 1.16.103
14 Plan, draw, estimate material, wire up and test different type of commercial and
computer networking wiring circuits as per Indian Electricity rules and taking care
of quality. 1.17.104 - 1.17.109

(xi)
 SYLLABUS

1st Year Duration: Six Months

Duration Reference Learning Professional Skills

Professional Knowledge
Outcome (Trade Practical)
(Trade Theory)
with Indicative hours
P r o f e s s i o n a l Make good quality 1. Implementation in the shop floor of Occupational Safety & Health
Skill 125 Hrs; electrical wire joints for the various safety measures. (2 hrs.) Basic safety introduction,
single and multi strand 2. Visit to the different sections of the Personal protection:-
Professional
conductors suitable for Institute. (3 hrs.) Basic injury prevention, Basic
Knowledge 35
applications with first aid, Hazard identification and
Hrs 3. Demonstration on elementary first
soldering following avoidance, safety signs for
aid. Artificial Respiration. (2 hrs.)
electrical safety Danger, Warning, caution &
precautions. 4. Practice on use of fire extinguishers.
personal safety message.
(3 hrs.)
Use of Fire extinguishers.
5. Occupational Safety & Health
Importance of housekeeping & good Visit & observation of sections.
shop floor practices. (3 hrs.) Various safety measures involved
6. Health, Safety and Environment in the Industry.
guidelines, legislations & regulations Concept of Standard
as applicable. Disposal procedure of Operation of electrical mains.
waste materials like cotton waste, Introduction of PPEs.
metal chips/burrs etc. (4 hrs.) Introduction to 5S concept & its
7. Basic safety introduction, Personal application.
protective Equipment (PPE):- Basic Response to emergencies eg;
injury prevention, Basic first aid, power failure, fire, and system
Hazard identification and avoidance, failure. (07 Hrs)
safety signs for Danger, Warning,
caution & personal safety message.
(3 hrs.)
8. Preventive measures for electrical
accidents & steps to be taken in
such accidents. (5 hrs.)

9. Demonstration of Trade hand tools. Identification of Trade-Hand tools-

(6 hrs.) Specifications. (07 hrs)
10.Identification of simple types-
screws, nuts & bolts, chassis,
clamps, rivets etc. (7 hrs.)
11. Use, care & maintenance of various
hand tools. Familiarization with
signs and symbols of Electrical
accessories. (12 hrs.)

12.Practice in using cutting pliers, Fundamental of electricity.

screw drivers etc. skinning the Electron theory- free electron,
cables, and joint practice on single Fundamental terms, definitions,
strand. (20 hrs.) units & effects of electric
13.Demonstration & Practice on bare current.
conductors joints--such as rat tail, (14 hrs)
Britannia, straight, Tee, Western
union Joints. (30 hrs.)
14.Practice in soldering & brazing- Solders, flux and soldering
measurement of Resistant and technique. Resistors types of
measurement of specific resistant. resistors & properties of
(15 hrs.) resistors.
(07 hrs)

(xii)
 15 Application of Wheatstone bridge in
measurement of resistance. (10 hrs.)

Professional Draw and set up 16. Demonstration and identification of types Introduction of National Electrical
Skill 50 Hrs; DC and AC of cables. (6 hrs.) Code 2011 Explanation, Definition
circuits including 17. Demonstration & practice on using and properties of conductors,
Professional
R-L-C circuits with standard wire gauge & micrometer. insulators and semi-conductors.
Knowledge
a c c u r a t e (6 hrs.) Voltage grading of different types
measurement of of Insulators, Temp. Rise
18. Practice on crimping thimbles, Lugs.
voltage, current, permissible
(5 hrs.)
resistance, power, Types of wires & cables standard
power factor and 19. Examination and checking of cables and
wire gauge Specification of wires
energy using conductors and verification of materials
& Cables-insulation & voltage
a m m e t e r , according to the span. (8 hrs.)
grades
voltmeter, ohm- -Low , medium & high voltage
meter, watt-meter,
energy meter, Precautions in using various types
power factor of cables / Ferrules.
meter and phase (07 hrs)
sequence tester
with proper care 20. Verification of Ohm’s Law. (2 hrs.) Ohm’s Law -
and safety. 21. Verification of Kirchhoff’s Laws. (3 hrs.) Simple electrical circuits and
22. Verification of laws of series and parallel problems. Reading of simple
circuits. (4 hrs.) Electrical Layout.
23. Verification of open circuit and closed Resistors -Law of Resistance.
circuit network. (3 hrs.) Series and parallel circuits.
24. Measuring unknown resistance using Kirchhoff’s Laws and applications.
Wheatstone bridge, voltage drop method. Wheatstone bridge principle and
(6 hrs.) its applications.
25. Experiment to demonstrate the variation Effect of variation of temperature
of resistance of a metal with the change on resistance. Different methods
in temperature. (7 hrs.) of measuring the values of
resistance.
(07 hrs)

Professional Plan, draw, 26. Practice on installation and overhauling Common Electrical Accessories,
Skill 25 Hrs; estimate material, common electrical accessories as per their specifications in line with NEC
wire up and test simple Electrical circuit / Layout. 2011-Explanation of switches lamp
Professional
different type of (10 hrs.) holders, plugs and sockets.
Knowledge
domestic wiring 27. Fixing of switches, holder plugs etc. in Developments of domestic
07 Hrs
circuits as per T.W. boards. (8 hrs.) circuits, Alarm & switches, with
Indian Electricity individual switches, Two way
28. Identification and use of wiring
rules and taking switch .Security surveillance, Fire
accessories concept of switching.
care of quality. alarm, MCB, ELCB, MCCB. (07
(7 hrs.)
Construction and hrs)
working of MCB &
ELCB. Test a
domestic wiring
installation using
Megger.

Professional Identify the type of 29. Assembly of Dry cell- Electrodes- Chemical effect of electric current-
Skill 75 Hrs; b a t t e r i e s , Electrolytes. (4 hrs.) Principle of electrolysis. Faraday’s
construction, 30. Grouping of Dry cells for a specified Law of electrolysis. Basic
Professional
working and voltage and current, Ni cadmium & principles of Electro-plating and
Knowledge
application of Ni- Lithium cell. (4 hrs.) Electro chemical equivalents.
21 Hrs
cadmium, lithium Explanation of Anodes and
31. Practice on Battery Charging,
cell, lead acid cell cathodes.
preparation of battery charging. (4 hrs.)
etc. Demonstrate

(xiii)
 their charging 32. Testing of cells, Installation of Lead acid cell-description,
and discharging, batteries, Charging of batteries by methods of charging- Precautions
c h o o s i n g different methods. (8 hrs.) to be taken & testing equipment,
appropriate 33.Practice on Electroplating and Ni-cadmium & Lithium cell,
method and anodizing, Cathodic protection. (5 hrs.) Cathodic protection.
carryout the Electroplating, Anodizing. Different
installation and types of lead acid cells. (07 hrs)
r o u t i n e
maintenance 34.Routine care & maintenance of Rechargeable dry cell, description
with due care Batteries. (25 hrs.) advantages and disadvantages.
and safety.
Care and maintenance of cells
Grouping of cells of specified
voltage & current, Sealed
Maintenance free Batteries, Solar
battery. (07 hrs)

35. Charging of a Lead acid cell, filling of Inverter, Battery Charger, UPS-
electrolytes- Testing of charging Principle of working. Lead Acid
checking of discharged and fully cell, general defects & remedies.
charged battery. (25 hrs.) Nickel Alkali Cell-description
charging. Power & capacity of
cells. Efficiency of cells. (07 hrs)

Professional Make choices to 36.Marking use of chisels and hacksaw ALLIED TRADES:
Skill 100 Hrs; carry out basic on flats, sheet metal filing practice, filing Introduction of fitting trade. Safety
jobs of marking true to line. (26 hrs.) precautions to be observed
Professional
out the 37. Sawing and planning practice. Practice Description of files, hammers,
Knowledge
components for in using firmer chisel and preparing chisels hacksaw frames & blades-
28 Hrs
filing, drilling, simple half lap joint. (24 hrs.) their specification & grades. Care
and riveting, & maintenance of steel rule try
fitting and square and files.
assembled
Marking tools description & use.
using different
Description of carpenter’s
components
common hand tools such as saws
independently.
planes, chisels mallet claw
hammer, marking, dividing &
holding tools-their care and
maintenance. (14 hrs)

38.Drilling practice in hand drilling & power Types of drills description & drilling
drilling machines. Grinding of drill bits. machines, proper use, care and
(8 hrs.) maintenance.
39. Practice in using taps & dies, threading Description of taps & dies, types
hexagonal & square nuts etc. (8 hrs.) in rivets & riveted joints.
40. Cutting external threads on stud and Use of thread gauge. (07 hrs)
on pipes, riveting practice. (9 hrs.)

41. Practice in using snips, marking & Description of marking & cutting
cutting of straight & curved pieces in tools such as snubs shears
sheet metals. (6 hrs.) punches & other tools like
42. Bending the edges of sheets metals. hammers, mallets etc. used by
(6 hrs.) sheet metal workers. Types of
soldering irons-their proper uses.
43. Riveting practice in sheet metal.
Practice in making different joints in Use of different bench tools used
sheet metal in soldering the joints. by sheet metal worker. Soldering
(13 hrs.) materials, fluxes and process.
(07 hrs)

(xiv)
Professional Draw and set up 44. Trace the magnetic field. (8 hrs.) Magnetism –
Skill 100 Hrs; DC and AC 45. Assembly / winding of a simple electro Classification of magnets,
circuits including magnet. (12 hrs.) methods of magnetising, magnetic
Professional
R-L-C circuits with materials. Properties, care and
Knowledge 46. Use of magnetic compass. (6 hrs.)
a c c u r a t e maintenance.
28 Hrs 47. Identification of different types of
measurement of
Capacitors. (10 hrs.) Para and Diamagnetism and Ferro
voltage, current,
magnetic materials. Principle of
resistance, power, 48. Charging and discharging of capacitor.
electro-magnetism, Maxwell’s
power factor and (8 hrs.)
energy using corkscrew rule, Fleming’s left and
49. Testing of Capacitors using DC voltage
a m m e t e r , right hand rules,
and lamp. (8 hrs.)
voltmeter, ohm- Magnetic field of current carrying
meter, watt-meter, conductors, loop and solenoid.
energy meter, MMF, Flux density, reluctance.
power factor B.H. curve, Hysteresis, Eddy
meter and phase current. Principle of electro-
sequence tester magnetic Induction, Faraday’s
with proper care Law, Lenz’s Law.
and safety. Electrostatics: Capacitor- Different
types, functions and uses. (14 hrs)
50. Determine the characteristics of RL, RC Alternating Current -Comparison
and RLC in A.C. Circuits both in series and Advantages D.C and A.C.
and parallel. (13 hrs.) Related terms frequency
51. Experiment on poly phase circuits. Instantaneous value, R.M.S. value
(8 hrs.) Average value, Peak factor, form
52. Current, voltage, power and power factor factor.
measurement in single & poly- phase Generation of sine wave, phase
circuits. (15 hrs.) and phase difference.
53. Measurement of energy in single and Inductive and Capacitive reactance
poly-phase circuits. (8 hrs.) Impedance (Z), power factor (p.f).
54. Use of phase sequence meter. (6 hrs.) Active and Reactive power, Simple
problems on A.C. circuits, single
Phase and three-phase system
etc. Problems on A.C. circuits.
Power consumption in series and
parallel, P.F. etc. Concept three-
phase Star and Delta connection.
Line and phase voltage, current
and power in a 3 phase circuits
with balanced and unbalanced
load. (14 hrs)
Professional Plan and install 55. Practice on Earthing – different methods Earthing- Principle of different
Skill 25 Hrs; Pipe & Plate of earthing.(13 hrs.) methods of earthing. i.e. Pipe,
earthing. Measure 56. Measurement of Earth resistance by Plate, etc Importance of Earthing.
Professional
earth resistance earth tester.(6 hrs.) Improving of earth resistance
Knowledge
by earth tester. Earth Leakage circuit breaker
07 Hrs 57. Testing of Earth Leakage by ELCB and
relay. (6 hrs.) (ELCB).
In absence of latest revision in
respective BIS provision for
Earthing it is recommended to
follow IEC guidelines. (07 hrs)

Professional Select and 58. Determine the resistance by Colour Basic electronics- Semiconductor
Skill 75 Hrs; perform electrical/ coding. (4 hrs.) energy level, atomic structure ‘P’
electronic 59. Identification of active/passive type and ‘N’ type.
measurements components. (5 hrs.)

(xv)
Professional with appropriate 60. Diodes-symbol - Tests - Construct & Type of materials –P-N-junction.
Knowledge instrument. Test Half wave rectifier ckt. (8 hrs.) Classification of Diodes – Reverse
21 Hrs 61. Full wave rectifier ckt. Bridge rectifier and Forward Bias,
ckt. (8 hrs.) Heat sink. Specification of Diode
PIV rating.
Explanation and importance of D.C.
rectifier circuit. Half wave, Full wave
and Bridge circuit.
Filter circuits-passive filter. (07 hrs)

ELECTRICAL MEASURING Type of measuring instruments –

INSTRUMENTS- MC & MI, Construction & working
62. Measurement of voltage, current & principles of Ammeter, Voltmeter,
resistance in different circuits. (5 hrs.) Ohm-meter ,Wattmeter, Energy
meter,
63. Direct & indirect measurement of
electrical power & energy. (6 hrs.) P.F. meter, frequency meter, multi
meter, clamp meter, Megger & earth
64. Calibration of energy meters. (6 hrs.)
tester. Introduction of Digital
65. Measurement of current and voltage meters. CT & PT. Tong tester / Clip
using CT & PT, Measurement of 3 on Meter. (14 hrs)
Phase energy using CT & PT. Phase
sequence meter, measure current and
voltage using Tong tester. (12 hrs.)
66. Power measurement by Two & Three
watt meter method Insulation resistance
test by Megger. (7 hrs.)
67. Measurement of earth resistance by
earth tester. (4 hrs.)
68. Calibration of indicating type analogue
instruments: voltmeter, ammeter, and
wattmeter. Measurement of soil
conductivity. Introduction of Digital
meters. (10 hrs.)

Professional Plan, draw, DOMESTIC WIRING - METHODS, Introduction and explanation of

Skill 150 e s t i m a t e INSTALLATION & TESTING- electrical wiring systems, cleat
Hrs; material, wire up 69. Demonstration & Practice on wiring, casing & Capping, CTS,
and test different connecting common electrical Conduit and concealed etc.,
Professional
type of domestic accessories in circuits and testing them I. E. Rules. Related to wiring,
Knowledge
wiring circuits as in series board. (8 hrs.) National Building codes for house
42 Hrs
per Indian wiring, specification and types,
70. Demonstration on Testing &
Electricity rules rating & material. (07 hrs)
replacement of different types of fuses.
and taking care of
(6 hrs.)
q u a l i t y .
Construction and 71. Identification of different wiring materials
working of MCB and their specifications. (6 hrs.)
& ELCB. Test a 72. Removing of insulation from assorted
domestic wiring wires and cables. (10 hrs.)
installation using 73. Demonstration and practice crimping
Megger. thimbles/lugs of various sizes. (8 hrs.)
74. Jointing practice with single and multi-
stranded conductors of different wires
and cables. (12 hrs.)

75. Layout on wiring boards. (5 hrs.) Branching of circuits with respect

76. Practice in P.V.C. insulated cable wiring to loads such as lighting and power.
on wood buttons with distribution board CTS/PVC Conduit-surface and
and number of points. (10 hrs.) concealed/ metal conduit/ PVC
casing and capping.

(xvi)
 IE rules regarding clip distance.
Fixing of screws, cable bending etc.
(07 hrs)

77. Practice of wiring: A) One lamp Description of different electrical

controlled by one SP switch, (B) Two fittings and accessories such as
lamps controlled by two independent lamp holders, switches, plugs
switches, (C) One lamp controlled by two brackets, ceiling rose, cut out etc.
2way switches (Staircase wiring), (D)One IS 732- 1863.Wiring materials used
lamp controlled by intermediate switch for P.V.C. cables I.E. rules, Indian
from three different locations, (E)Hospital standards regarding the above
wiring, (F)Tunnel/ Godown wiring, wiring such as-clip distance fixing
(G)Hostel wiring, (H)Bell Buzzer of screws, cable bending etc. (07
Indicator wiring, (I)Domestic wiring hrs)
practice. (15 hrs.)
78. Demonstration and practice of using Description of Rowel tools and
Rowel tools. (8 hrs.) Rowel plugs, their sizes, plugging,
79. Demonstration and practice of casing compound, plugs- wall jumper and
and capping wiring. (10 hrs.) their sizes and uses. Introduction
to estimation procedure, P.V.C.
80. Testing of wiring installation by using
casing and capping materials, sizes
Megger. (7 hrs.)
and grades etc. (07 hrs)
81. Demonstration and practice in cutting Conduit pipe wiring materials and
and threading conduit pipes. (6 hrs.) accessories, types and sizes of
82. Cold and hot bending of pipes. (6 hrs.) conduit. (07 hrs)
83. Fitting of conduit accessories. (13 hrs.
84. Preparation of conduit threads using Layout of Light points, fan points
different fittings and use of running etc. Layout of heating leads etc.-
threads wiring in conduit, using metal their controls, main switches,
clad 3 pin plug, Earthing the conduit distribution boards as per I.E. rules.
using earth clips and earth wire. (20 hrs.) I. E. Rules for earthing conduits
using earth clips and earth wire as
per IS 732-1863. (07 hrs)

Professional Plan and execute ILLUMINATION:- Introduction of Illumination- Terms

Skill 25 Hrs; e l e c t r i c a l 85. Installation of - Neon Sign tube, Mercury & definitions, laws of illumination,
illumination vapour (H.P. & L.P.), Sodium vapour, illumination factors, intensity of light
Professional
system viz. FL Halogen Lamps, single tube, double –importance of light, colour
Knowledge
tube, HPMV lamp, tube, Metal halide lamps. Emergency available.
07 Hrs
HPSV lamp, light. (9 hrs.) Construction, working &
Halogen & metal applications of – Incandescent
86. Practice on decoration lighting. (7 hrs.)
halide lamp, CFL, lamp, Fluorescent tube, CFL, Neon
LED lamp etc. 87. Practice on using LUX Meter. (4 hrs.)
sign, Halogen, Mercury vapour and
88. Installation and testing of CFL Lamps types, sodium vapour etc.
and LED Lamps (5 hrs.) Decoration lighting, Drum Switches
etc. (07 hrs)
Professional Plan, draw, INDUSTRIAL WIRING- Connections of different types of
Skill 75 Hrs; estimate material, 89. Tests on insulating materials. (15 hrs.) motors used in industry, their
wire up and test normal methods of wiring, Control ,
Professional 90. Measurement of insulation resistance,
different type of starting and protection devices-their
Knowledge of commercial and industrial installation
industrial wiring connections, layouts and earthing
21 Hrs Additional practice in conduit wiring.
circuits as per Code practice for earthing of
(30 hrs.)
Indian Electricity Industrial Wiring.
rules and taking 91. Industrial power wiring involving single
Wiring methods & types in
care of quality. phase & 3phase motors with switches
workshop & factories. (21 hrs)
& starters. (30 hrs.)

(xvii)
Professional Plan, draw, COMMERCIAL WIRING- Wiring in commercial building- their
Skill 75 Hrs; estimate material, 92. Inverter wiring./ Control panel wiring / special precautions as per I.E.
wire up and test multi-storeyed building wiring. (15 hrs.) rules.
Professional
different type of Introduction to LAN wiring. (07 hrs)
Knowledge 93. Introduction to LAN wiring. (7 hrs.)
commercial and
21 Hrs
c o m p u t e r
94. Installation of 1 ph. and 3 ph. on line / Power drives - Introduction, types,
networking wiring
off line UPS wiring. (15 hrs.) advantages & disadvantages.
circuits as per
Indian Electricity 95. Testing of Industrial wiring and UPS UPS- Introduction, types, Load
rules and taking wiring installation. (20 hrs.) calculation, Backup time
care of quality. calculation. (07 hrs)
96. Straight and cross crimping of RJ-45 Computer networking - Identification
cable. (08 hrs.) of network hardware / component.
97. Crimping of co-axial cable, proper CAT-6 cable, RJ-45.
installation of co-axial cable from dish DTH- Introduction of direct to home
antenna to Television set. (10 hrs.) system, Music channel wiring/
interconnecting couplers. (07 hrs)

Professional Plan, draw, 98. Industrial wiring installations for mixed General idea of fixing meter boards
Skill 50 Hrs; estimate material, load, both light and power. (9 hrs.) & taking service connection. Sealing
wire up and test 99. Layout of L.V. AC/DC machines and their of I.C. cut out & meters as per I.E.
Professional
different type of panels. (3 hrs.) Rules, General Electric Appliances
Knowledge
industrial wiring 100. Wiring of Low power A.C./ D.C. using heating effect – their
14 Hrs
circuits as per machines in metal conduit system as capacities, voltage ranges,
Indian Electricity per I.E. Rules. (10 hrs.) Calculation of current. (07 hrs)
rules and taking
101. Testing of wiring installation. (3 hrs.)
care of quality.
102. Wiring of different circuit using Single Explanation of inter connection
core cable use for 2 ways, intermediate wiring circuits in the main building
master switches etc. (20 hrs.) and auxiliary blocks, meter boards
103. Testing of wiring installation. (5 hrs.) and its locations. Study of layout
symbols in the preparation of layout
diagrams. (07 hrs)

Professional Plan, draw, COMPUTER AWARENESS: Block diagram of computer, main

Skill 50 Hrs; estimate material 104. Identification of Computer Parts, parts inside the system unit, ports
wire up and test Switching ON/OFF of PC, Safety & connectors, of PC parts &
Professional
different type of Precautions. (5 hrs.) peripherals associated with PC
Knowledge
commercial and 105. Identifying and using Windows, like like-keyboard, Mouse, Printers,
14 Hrs
c o m p u t e r folders, files, Editing and saving. (12 hrs.) Scanners, Camera, Modem,
networking wiring External Storage Devices & UPS.
106. Windows Explorer, Notepad, Paint and
circuits as per Features of Operating System like
calculator. (12 hrs.)
Indian Electricity M.S. Windows, Components of
rules and taking OFFICE PACKAGE& INTERNET:
Windows- Calculator, Notepad,
care of quality. 107. Using /Practicing WORD, EXCEL, Paint, Windows Explorer.
POWER POINT for communication.
INTERNET: Websites, Browsing,
(16 hrs.)
Downloading Creating and Using E-
108. Documentation. (2 hrs.) mail ID’s Using it for
109. Internet Practicing – Browsing/ Creating Communications. (14 hrs)
Email, Downloading. (3 hrs.)
In plant training / Project work

(xviii)
Power Exercise 1.1.01
Wireman - Safety Practice

Practice on implementation of various sagety measures in the shop floor

Objectives: At the end of this exercise you shall be able to
• follow the implementation guide lines in the shop floor for
- general safety
- personal safety
- machine safety
• prepare the flow chart for implementation of safety measures in the shop floor
• draw the bar-chart for shaving the cause for major and minor accidents happend in this floor.

Requirements
Tools and Instruments/equipment Materials
• Pencil HB - 1 No. • Flow chart showing safety implementation - 1 No.
• Chart paper - 1 No. • Bar chart (Showing cause for accidents) - 1 No.
• Eraser - 1 No.

PROCEDURE
TASK 1: Follow the implemetation guide lines for general, personal and machine safety in shop floor
1 Read and interpret are safety guide lines (Do's and The safety implementation guidelines in shop
Don't in table -1. floor given in table -1, instruction as Do's and
2 Follow and implement these safety guidelines in the Dont's form.
shop floor for general, personal and machine safety.
Table 1
Do's Dont's
• Keep the floor and gauge ways clear • Don't leave the machine which is in motion
• Move with care in the workshop • Don't touch (or) handle any equipment machine unless
authorised to do so.
• Use the correct tools for the job • Don't walk under suspended loads
• Keep the tools at their proper place • Don't have unwanted talks anway workers
• Replace work out or damaged tools immediately
• Ensure adequate light in workshop
Personal safety
• Wear a one piece over all • Don't use ties and scares
• Wear safety shoes or boots • Never lean on the machine
• Cut the hair short • Don't remove generals when the machine is in motion
• Concentrate on your work • Don't distract the attention of others
• Do things in the methodical warn
• Ensure that electrical connect as and metal parts • Don't use any faulty electrical equipment
are properly contracted
Machine safety
• Keep the machine always clear • Don't try to shop a running machine units bare hands
• Suit 'OFF' the machine immediately of fault • Do not operate the machien without knowing the
occurs procedure
• Stop the machine before changing the speed • Do not adjust with tab unless the power in 'OFF'

1
 • Check the rated supply before starting the
machine
• Replace wornout parts in the machine in • Don't start the machine unless all the safety guards
immediately are in problem

__________

TASK 2: Prepare the flow chart for implementation of safety measure in the shop floor
1 Visit the shop floor and have visualy look for any fault Flow chart for safety implementaion in the shop
and damages. floor
2 Analyse the unsage problems and their status. Visit to the workshop

Every one in the shop floor must a wave and
It is not remedy analyse the past/previous if yes safety
adopt the sop floor safety and train others also
problems solved in the shop
to follow...

3 Prepare a flow chart for implementation of safety Analyse the current status if yes about safety in the
measures for your shop floor. shop

one typical flow chart -1 is given for your
Identify the safety problems and list out
referance.

4 Get it checked by your Instructor. Train the workers for solving the safety problems

Implement the safety activities (5s - concept and
kaizard)

Benefits and results
__________

TASK 3: Draw the bar chart for safety implementation in workshop

1 List out the number accidents (minor (or) major) occured Causes for accidents
in previous three years (atleast)
a Impact routine work/fatal.
2 Draw the bar chart keeping the number of years in 'X'
b Contribute to work may causes to work delay/incidents
axis and number of accidents (major (or) minor) accured
or recordable injuries.
during the particular year in 'Y' axis.
c Issure is their not effected to routine work/near miss
Sample bar graph to share for your chat
accidents.
reference with number of minor and mojor
accidents occuring during the previous 3 years. 3 Get it checked by your Instructor.

__________

2 Power: Wireman (NSQF Level - 4) - Exercise 1.1.01

Power Exercise 1.1.02
Wireman - Safety Practice

Visit to the different sections of the Institute and draw the layout
Objectives: At the end of this exercise you shall be able to
• visit the various sections/trade in your ITI and draw the layout of your ITI
• record the telephone numbers of the ITI office, hospitals, police station and fire station
• draw the layout of your section.

PROCEDURE
TASK 1: Visit various sections of the ITI and draw the layout of your ITI

Instructor will lead the new trainees to various sections of the ITI.

1 Visit the various sections in your ITI and identify the 4 Collect the telephone numbers of the ITI office, nearest
sections of the ITI. List the trades and record it in your hospitals, nearest police station and the nearest fire
note book. station and record.
2 Collect the information about the staff members in each 5 Draw the layout of your ITI showing various trades.
trade.
Note: A Sample layout of the ITI (Fig 1) is given
3 Identify the location of the ITI with details abouit the for your reference. Now draw the new layout
railway and bus stations in the locality and note down of your ITI, with the trades/sections.
the list of bus route numbers which ply near the ITI.

__________
TASK 2: Draw the layout of your wireman s ection in the ITI
1 Draw the plan of your section to a suitable scale in a 3 Draw the layout of the machines, work benches, panels
separate sheet of paper (A4 size). and furniture.
2 Take the length and the breadth measurements of
machine foundations, work benches, panels, wiring
cubicles, doors, windows, furniture, etc.

3
 The section plan should be in the same scale
as in step 1 as per the actual placement of the
machine foundations, panels, furniture, work
benches etc.
Note : The sample layout of a typical wireman
trade section is given for your reference (Fig
2). You have to draw your section's is layout
using the sample as reference.

__________

4 Power: Wireman (NSQF Level - 4) - Exercise 1.1.02

Power Exercise 1.1.03
Wireman - Safety Practice

Demonstration on elementary first aid. Artificial Respiration

Objectives: At the end of this exercise you shall be able to
• rescue a victim from electric shock
• apply respiratory methods
- Nelson's arm - Lift back pressure method
- Schafer's method
- mouth to mouth method
- mouth to nose method.

Requirements
Tools and Instruments/equipment • Wooden stick - 1 No.
• 2 persons for demonstration purpose
• Control panel arrangement - 1 No.
• Motor - 1 No.
• Rubber mat - 1 No.

PROCEDURE
TASK 1: Rescue a person (mock victim) from live electric supply (simulated).

2 Move the victim safely away from the `live` equipment

by disconnecting the supply or using any insulating
material.
Do not run to switch 'OFF' the supply that is far
away.
Do not touch the victim with bare hands until
the circuit is made dead or the victim is moved
away from the equipment.
Push or pull the victim away from the point of
contact of the live equipment, without causing
serious injury to the victim.
3 Move physically the victim to a nearby place.
4 Check for the victim's natural breathing and
1 Observe the person (mock victim) receiving an electric consciousness.
shock. Interpret the situation quickly.
5 Take steps to revive breathing if the victim is
unconscious and not breathing.
__________

TASK 2 : Revive breathing from victim by Nelson’s arm-Lift back pressure method

Nelson’s arm-lift back pressure method must 3 Place your hands on the victim’s back beyond the line
not be used when there are injuries to the chest of the armpits, with your fingers spread outwards and
and belly. downwards, thumbs just touching as in Fig 2.

1 Place the victim with his arms folded with the palms 4 Gently rock forward keeping your arms straight until
one over the other and the head resting facing the ground they are nearly vertical, and steadily keep pressing
with his cheek over the palms. the victim’s back as in Fig 3 to force the air out of the
victim’s lungs.
2 Kneel on one or both knees near the victim’s head.

5
5 Synchronise the above movement of rocking back wards
with your hands sliding downwards along the victim’s
arms, and grasp his upper arm just above the elbows
8 Keep the victim warm with a blanket, wrapped around
as in Fig 4. Continue to rock backwards.
him or with hot water bottles or warm bricks. Stimulate
6 As you rock back, gently raise and pull the victim’s blood circulation towards the heart by stroking the
arms towards you as in Fig 5 until you feel the tension insides of the arms and legs.
in his shoulders. To complete the cycle, lower the
9 Keep him in the lying position and do not let him exert
victim’s arms and move your hands up to the initial
himself.
position.
Do not give him any stimulant, until he is fully
7 Continue artificial respiration till the victim starts to
conscious.
breathe naturally. Please note, in some cases, it may
take hours.
__________

TASK 3 : Revive breathing in the victim by Schafer’s method

Do not use this method when the victim has

injuries on the chest and belly.
1 Lay the victim on his belly, one arm extended direct
forward, the other arm bent at the elbow and with the
face turned sideward and resting on the hand or forearm
as in Fig 6.
2 Kneel when the victim is astride, so that his thighs are
between your knees with your fingers and thumbs
positioned as in Fig 6.

6 Power: Wireman (NSQF Level - 4) - Exercise 1.1.03

3 With the arms held straight, slowly swing forward so
that the weight of your body is gradually brought to
bear upon the lower ribs of the victim to force the air
out of the victim’s lungs as in Fig 7.

5 After two seconds, swing again forward and repeat the

cycle twelve to fifteen times per minute.
6 Continue it till the victim begins to breathe naturally.
4 Swing backwards immediately and removing all the
pressure from the victim’s body as in Fig 8, to allow
the lungs to fill with air.
__________

TASK 4: Revive breathing in the victim by mouth-to-mouth method

Use this method when the victim has injured

on the chest (or) belly
1 Lay the victim flat on his back and place a cloth roll
under his shoulders to ensure that his head is thrown
well back. (Fig 9)

4 Take a deep breath and place your mouth over the

victim’s mouth as in Fig 12 making airtight contact. 5
Pinch the victim’s nose shut with the thumb and
2 Tilt the victim’s head back so that the chin points forefinger.
straight upwards. (Fig 10) If you dislike direct contact, place a porous
cloth between your mouth and that of the
victim’s. For an infant, place your mouth over
the infant's mouth and nose. (Fig 12)

3 Grasp the victim’s jaw as in Fig 11, and raise it upwards

until the lower teeth are higher than the upper teeth
you may also place your fingers on both sides of the 5 Blow into the victim’s mouth (gently in the case of an
jaw near the victim's ear lobes and pull upward. infant) until his chest rises. Remove your mouth and
release the hold on the nose, to let him exhale, turning
Maintain this jaw position throughout the your head to hear gushing the out of air.
duration to revivel respiration to prevent the
tongue from blocking the air passage. The first 8 to 10 breathings should be as rapid
as the victim responds. Thereafter the rate
should be slowed down to about 12 times per
victim's minute (20 times for an infant).
Power: Wireman (NSQF Level - 4) - Exercise 1.1.03 7
 If air cannot be blown in, check the position of
the victim’s head and jaw and recheck the
mouth for obstructions. Then, try again more
forcefully. If the chest still does not rise, turn
the victim’s face down and strike his back
sharply to dislodge obstructions.
Sometimes air enters the victim’s stomach as
evidenced is the swelling of the stomach. Expel
the air by gently pressing the stomach during
the exhalation period.

__________
TASK 5: Revive breathing from victim by Mouth-to-Nose method

Use this method when the victim’s mouth will

not open, or has a blockage you cannot clear.
1 With the fingers of one of your hand that keep the
victim’s lips firmly shut. Seal your lips around the
victim’s nostrils and breath the air into him. Check to
see if the victim’s chest is rising and falling. (Fig 13)
2 Repeat this exercise at the rate of 10-15 times per
minute till the victim responds.
3 Continue this exercise till the arrival of the doctor.

__________

8 Power: Wireman (NSQF Level - 4) - Exercise 1.1.03

Power Exercise 1.1.04
Wireman - Safety Practice

Practice on use of fire extinguishers

Objectives: At the end of this exercise you shall be able to
• select fire extinguishers according to the type of the fire
• operate the fire extinguisher
• extinguish the fire.

Requirements
Tools and Instruments/equipment
• Fire extinguishers-CO2 - 1 No.
• Scissors 100mm - 1 No.
• Cell phone - 1 No.

PROCEDURE
1 Alert people in the surrounding area by shouting fire, 4 Switch "OFF" all electrical power supply.
fire, fire when you see fire (Fig 1a).
Do not allow people to go near the fire.
2 Inform fire service or arrange to inform them immediately
5 Analyze to identify the type of fire. Refer Table1.
(Fig 1c).
6 Assume that it is type D fire (fire on electric equipment).
3 Open the emergency exit and ask the people inside
the area to go away (Fig 1d).

9
 Table 1

Class 'A': Wood, paper, cloth, solid material

Class 'B': Oil-based fire (grease, gasoline,oil) and

liquefiable solids

Class 'C': Gas and liquefied gases

Class 'D': Metals and electrical equipment

10 Power: Wireman (NSQF Level - 4) - Exercise 1.1.04

7 Select CO2 (carbon dioxide) fire extinguisher. 12 Slowly squeeze the handle lever to discharge the agent.
(Fig 9)
8 Locate and take the CO2 fire extinguisher as in Fig 1b.
13 Sweep from side to side approximately 15 cm over the
9 Break the seal. (Fig 6)
fuel fire until the fire is put off. (Fig 9)

Fire extinguishers are manufactured for use

from a distance.
10 Pull the safety pin from the handle. (Fig 7) (the Pin is
Caution
located at the top of the fire extinguisher.) (Fig 7)
• While putting OFF fire, the fire may flare up.
• Do not panic so long as it is being put off promptly
• If the fire does not respond well even after you have
used the fire extinguisher, move away from the fire point.
• Do not attempt to put out a fire when it emits toxic
smoke. Leave it to the professionals.
• Remember that your life is more important than the
property. So do not take risks.
In order to remember the simple operation of
11 Aim the extinguisher nozzle or hose at the base of the
fire extinguisher, remember P.A.S.S.
fire. (Fig 8)
This will help to use the fire extinguisher.
Keep your self low.
P for pull
A for aim
S for squeeze
S for sweep

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.1.04 11

Power Exercise 1.1.05
Wireman - Safety Practice

Practice on occupational Safety and Health Importance of housekeeping and

good shop floor practices
Objectives: At the end of this exercise you shall be able to
• read and interpret the of occupational safety and health
• practice an house keeping activities based an 5s concept for good shop floor.

Requirements
Tools and Instruments/equipment Materials
• Portable vacuum cleaner/blower - 1 No. • 5s concept chart - 1 No.
• Emery sheet-'O' grade - 1 No.
• Dusting cloth - as required.
• Dust bin - 3 Nos .
(labelled)

PROCEDURE
TASK 1: Read and interpret the importance of occupational safety health

1 Read and interpret the following prints for occupational 4 Make and ensure for an accidental free industrial
safety health importance. environment.
2 Follow the occupational safety health importance, given 5 Maintain and improves the movable of employees.
in table 1, wherever applicable.
6 Take necessary steps to reduce absebtee in.
3 Keep the employees heath and safety always in good
7 Take efforts to enhance productivity.
condition for successful function of industry.

__________

TASK 2: Practice on house keeping activities based 5s - concept for good shop floor

Switch OFF all the machinery and equipment Do not remove lubricants in the machine while
before starting the cleaning process. Use a wiping/cleaning.
mask or cover the mouth and nose.
6 Use vacuum cleaners to suck dust from areas where a
brush or cloth cannot help.
Instructor has to brief the Japanese 5S concept
to the trainees before starting the work. 7 Collect the waste materials found in the lab segregrate
  the organic, inorganic, metal scraps and put it in the
Sort
specified dustbin, as shown in Fig 1.
Set in order
Dusting and cleaning can be arranged by
Shine 5s - concept dividing the trainees into groups under the
Standardise supervision of the instructor.

Sustain 8 Clean places where water or oil has been spilt on the
floor
1 Identify the areas/equipment/machine that need to be Note down abnormal things that you noticed
cleaned. while cleaning and report it to the instructor to
2 Keep the movable items in one place and group them. take corrective action.

3 Clean the dust carefully, without damaging any part/ 9 Put all the materials and equipment used for cleaning
connection in the machine / equipment, using a cloth. in their respective places.

4 Use dusting cloth on areas that are wired. 10 Inspect and ensure that all machines are working after
cleaning in the presence of the instructor.
5 Remove rust on parts of the equipment (or) devices
using an emery sheet.

12
11 Discuss abnormal things that you came across while
cleaning with the instructor. Prepare a report if the
instructor asks for it
Instructor may assign trainees the responsibilty
of cleaning in batches. Disposal of waste may
be organised as a routine actvity by
coordinating with the stores.

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.1.05 13

Power Exercise 1.1.06
Wireman - Safety Practice

Interpret Health, Safety and Environment guidelines, legislations and

regulations as applicable. Disposal procedure of waste materials like cotton
waste, metal chips/burrs etc
Objectives: At the end of this exercise you shall be able to
• read and interpret and follow the guidelines for health, safety and environment
• read and interpret the applicable legislations and regulation
• identify and segregate the different type of waste materials for disposal
• seperate the cotton waste and dispose it.

Requirements
Tools and Instruments/equipment • Assorted waste materials - as avl.
• Health, safety environment guide
• Shovel - 1 No.
lines chart - 1 No.
• Platic metal bins - 4 Nos.
• Legislations & regulations - 1 No.
• Trolly with wheels - 3 Nos.
• Brush and gloves - 1 pour.

PROCEDURE
TASK 1: Read and interpret and follow the guidelines for health, safety and environment, EHS guide lines
1 Environmental c Physical, chemical, biological and radiological
hazards
a Air emissions and ambient air quality
d Personal protective equipment
b Energy conservation
3 Community health and safety
c Waste water and ambient water quality
a Water quality and availability
d Water conservation
b Structural safety of project infrastructure
e Hazardous materials management
c Life and fire safety
f Waste management
4 Construction and Decommissioning
g Noise
a Environment
h Contaminated land
b Occupational health and safety
2 Occupational health and safety
c Community health and safety
a General facility design and operation
b Communication and Training
__________

TASK 2: Preparation of a list for the OHAS

1 Preparation of a list for the OHAS Regulations d Training of employees for emergency preparation
and response by practicing mock test.
a Providing an authority for responsibility and
accountability. e Maintaing records for measurement and monitoring
performance of OHAS periodical health check.
b Improvement at employees competence, training
and awarness. f Internal audit to be conducted as per planned
schedule.
c Motivation of employees for communication
participation and consultation.

__________

14
TASK 3: Identify and segregate the waste materials for disposal
1 Collect all the waste materials in the workshop. 3 Sort waste materials as saleable, non saleable, organic
and inorganic materials.
2 Identify and segregate them like cotton waste, metal
chips, chemical waste and electrical waste (Fig 1) 4 Record the sorted waste material and fill Table-1.
separately and label them.

Table-1
SI.No. Name of the waste material Quantity Saleable or non Saleable

5 Arrange at least 3 trolleys with wheels for disposal. 6 Put the cotton waste in the cotton trolly and similarly
Stick label on each trolly as "Cotton Waste", "Metal put the metal chips waste and others in the respective
Chips" and "others". (Fig 2) trolleys.

7 Keep 4 more bins to collect saleable scrap, non

saleable scrap, organic waste and Inorganic waste and
label them. (Fig 3)

Power: Wireman (NSQF Level - 4) - Exercise 1.1.06 15

 __________

TASK 4: Separate the cotton waste and dispose it

1 Collect the chips by hand shavel with the help of a 5 Collect all the saleable material and non salable one
brush. seperately and put them in the respective bins.
2 Clean the floor if oil has been spilt. 6 Collect all the non-saleable materials like cotton waste,
paper waste, wooden pieces, etc., and keep them in
Do not handle the chip with bear hand.
the respective bin as in Fig 3.
Separate the chip according to the metal.
7 Check the non-saleable material (organic) and send it
3 Separate the cotton waste and store it in the bin provided
for disposal by burning after getting approval.
for the purpose.
8 Check the saleable material and segregate like
4 Store the each category in the assigned bins.
Aluminium, Copper, Iron, Screws, nuts and other items
Each bin have respective label. separately and send it to the stores for disposal by
auction (or) as per recommended procedure.
__________

16 Power: Wireman (NSQF Level - 4) - Exercise 1.1.06

Power Exercise 1.1.07
Wireman - Safety Practice

Practice on use of Personal Protective Equipment (PPE), Follow the prevention

procedure for basic injury and basic first aid, Identify, different hazards and
avoidance and identify use safety signs for personal safety measure
Objectives: At the end of this exercise you shall be able to
• identify and name the PPEs to the corresponding types of protection and write their uses
• follow the prevention procedure for basic injuries
• practice on basic first aid
• identify the different hazards with avoidance methods
• identify the different safety signs and their uses.

Requirements
Tools and Instruments/equipment • Basic first aid chart - 1 No.
• Safety signs chart - 1 No.
• Chart showing different type of PPEs - 1 No.
• Occupational hazards chart - 1 No.
• Real PPEs (available in section) - 1 No.
• Chart showing the prevention of injuries - 1 No.

PROCEDURE
TASK 1: Identify the personal protective equipment and their uses

Instructor may arrange the available different 1 Identify the different types of PPEs and write their
types of PPEs in the table or provide the chart names with the help of the chart and write in Table 1.
showing the PPEs. Instrcutor may also explain 2 Write the type of protection and from Fig 1 to 9 uses in
the types of PPEs and their uses, and the the space provided against each PPE in Table 1.
hazards for which each type is used.

Table 1
Sl. Sketches Name of Type of Uses
No. PPE protection
1

17
Sl. Sketches Name of Type of Uses
No. PPE protection
3

18 Power: Wireman (NSQF Level - 4) - Exercise 1.1.07

 Sl. No. Sketches Name of Type of Uses
PPE protection

3 Get it checked by your instructor.

__________

TASK 2: Follow the prevention procedure for basic injuries in work place
Chart 1 - Instruction to be displayed • Continually cultivate a safety standard of the jobs to
the employees with regular communication.
• Inspect vehicles before and after use "DRIVE SAFETY"
• Employees to be educated to know their
• Keep the lifiting load close to your body.
responsibilities.
• Don't twist while lifting.
Power: Wireman (NSQF Level - 4) - Exercise 1.1.07 19
• Establishing a health and safety program. Chart 2 - Examples of a workplace inspection report
• Ensure covers for rotating machineries. Inspection Location ____________________________
• Ensure double earthing for electrical equipments. Dated Inspection ______________________________
Department Areas Covered _______________________
Time of Inspection ______________________________

Observation
Item & Hazards Repeat Item Y/N Recommended Responsible Date
Location Observed action Person

Chart 3 - Periodical check up of employees

occupational heath and safety

1 Drinking water PH Value

2 Eye Testing

3 Vacunation

4 Food and accomdation

5 Sewage water treatment plant

6 Noise pollution value

7 Air pollution value

__________

TASK 3: Hazards identification and avoidance

The following hazards are normally occurs in the work
S.No Name of PPE To Avoid Hazard
place. Physical, chemical, Ergonomic and psychosocial
hazards. 1 Helmet
Fill the related hazards for given 2 Goggles
Which are the hazards avoid by using the PPE is given 3 Slip resistance shoe
below 4 Laboratory coat
5 Shoulder pad
6 Rubber cloves
7 Safety shoes
8 Safety belt

__________

20 Power: Wireman (NSQF Level - 4) - Exercise 1.1.07

TASK 4: Identify power safety signs for ranger, warning cautional and personal safety

Instructor may provide charts with various 1 Identify the signs and their categories from the chart.
safety signs for the road safety signs in traffic 2 Write the name, categories, meaning and description
signals. Then, explain the categories meaning of each sign and its place of use in Table 1.
and colour. Ask the trainees to identify the signs
and record it in Table 1.

Table 1
Sl. No. Safety signs Name of the sign and category Place of use

Power: Wireman (NSQF Level - 4) - Exercise 1.1.07 21

Sl. No. Safety signs Name of the sign and category Place of use

10

11

22 Power: Wireman (NSQF Level - 4) - Exercise 1.1.07

Sl. No. Safety signs Name of the sign and category Place of use

12

13

__________

TASK 5: Identify the road safety signs and traffic signal signs

Instructor will explain all the road safety signs

and traffic signal signs
1 Identify the sign and give details of its kind and meaning
in Table 2.
2 Get it checked by the instructor

Table 2
Figure Number Label Kind of road sign Name of the signal Meaning of the sign

1 a

2 b

3 c

4 d

5 e

6 f

7 g

8 h
__________
Power: Wireman (NSQF Level - 4) - Exercise 1.1.07 23
Power Exercise 1.1.08
Wireman - Safety Practice

Preventive measures for electrical accidents and steps to be taken in such

accidents
Objectives: At the end of this exercise you shall be able to
• practice and follow preventive safety rules to avoid electrical accidents
• rescue the electric shock victim.

Requirements
Materials • Wooden stool - 1 No.
• Ladder - 1 No.
• Heavy insulated screwdriver 200 mm - 1 No.
• Safety belt - 1 No.
• Electrical safety chart (or) display - 1 No.
• Gloves - 1 No.
• Rubber mat - 1 No.

PROCEDURE
TASK 1: Practice and follow preventive safety rules to avoid electrical accidents
1 Do not work on live circuits. If unavoidable use rubber 8 Open the main switch and make the circuit dead.
gloves or rubber mats.
9 Do not stretch your hands towards any moving part of
2 Do not touch bare conductors. the rotating machine and around moving shafts.
3 Stand on a wooden stool or an insulated ladder while 10 Use always always earth connection for all electrical
repairing live electrical circuits/appliances or replacing appliances along with 3-pin sockets and plugs.
fused bulbs.
11 Do not connect earthing to the water supply electrical
4 Stand on rubber mats while working, operating switch lines.
panels, control gears, etc.
12 Do not use water on electrical equipment.
5 Use always safety belts while working on poles or
13 Discharge static voltage in HV lines/equipment and
highrise points.
capacitors before working on them.
6 Use screwdrivers with wooden or PVC insulated handle
14 Keep the workshop floor clean and tools in good
when working on electrical circuits.
condition.
7 Replace (or) remove fuses only after switching off the
circuit switches.
__________

TASK 2: Rescue the electic shock victim

1 Proceed with treatment as early as possible without
panic or becoming emotional.
2 Switch off the power or remove the plug or wrench the
cable free.
3 Move the victim from contact with the live conductor by
using dry non-conducting materials like wooden bars.
(Fig 1 & 2)
Avoid direct contact with the victim. Wrap your
hands with dry material if rubber gloves are
not available. If you are uninsulated, do not
touch the victim with your bare hands.

24
 8 Cover the burnt area with pure running water.
9 Clean the burnt area using a clean cloth/cotton.
10 Send someone to call the doctor immediately.
In case of severe bleeding
11 Lay the patient flat.
12 Raise the injured part above the body level. (If possible)
13 Apply pressure on the wound ,as long as necessary,
to stop the bleeding. (Fig 4)

4 Keep the patient warm and at mental rest.

Ensure that there is good air circulation. Seek
help to shift the patient to a safer place. If the
victim is aloft, take steps to prevent him from
falling.
5 Loosen the clothing near the neck, chest and waist
and place the victin in a relaxed position, if the victim 14 Cover the injured area with a clean pad and bandage
is unconscious. firmly, if it is a large wound. (Fig 5)
6 Keep the victim warm and comfortable. (Fig 3)

7 Send someone to call the doctor, in case of electric

burns.
If the victim has electrical burns due to shock,
it may be very painful and is dangerous. If a
large area of the body is burnt do not give If bleeding is severe, use more than one
treatment. Give first-aid as given in step 8 dressing.
15 Initiate right methods of artificial respiration, if the person
in unconscious

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.1.08 25

Power Exercise 1.2.09
Wireman - Hand Tools - Wire Joints - Soldering

Demonstration of Trade hand tools

Objectives: At the end of this exercise you shall be able to
• identify tools and draw their sketches.

Requirements
Tools and Instruments/equipment • Bradawl (6 mm x 150 mm) - 1 No.
• Gimlet (4 mm x 150 mm) - 1 No.
• Combination plier (150 mm) - 1 No.
• Ratchat brace (6 mm) - 1 No.
• Long round nose plier (200 mm) - 1 No.
• Rawl jumper holder with bit No. 8 - 1 No.
• Screwdriver (150 mm) - 1 No.
• Triangular file bastard (150 mm) - 1 No.
• Firmer chisel (12 mm) - 1 No.
• Saw-tooth setter - 1 No.
• Wood rasp file (250 mm) - 1 No.
• Flat file bastard (250 mm) - 1 No.

The instructor shall arrange for the necessary tools/available in the sections on the table and demonstrate
to identify the tools.

PROCEDURE
TASK 1: Identify tools with specification and draw their sketches

Assumption - A set of trainees tool kit and 1 Identify the tools on the table with specification given.
specified tools as given in this exercise are 2 Draw a neat sketch against each item.
displayed on the workbench. Trainees are
required to identify the tools from the In case the specifications are different write
specifications given and draw the sketch of the the correct specification of the items given to
tools in the space allotted for the purpose. you.

Table 1
Sl. No. Name of tool with specification Sketch of tools

i Combination plier - size 150 mm,

ii Long round nose pliers 200 mm,

iii Screwdriver 150 mm

iv Firmer chisel 12 mm

v Wood rasp file 250 mm

vi Flat file bastard 250 mm

vii Bradawl 6 mm x 150 mm square-pointed

viii Gimlet 4 mm x 150 mm

ix Ratchet brace 6 mm capacity

x Rawl jumper holder with bit No.8

xi Triangular file bastard 150 mm

3 Get your sketches checked by your instructor.

__________
26
Power Exercise 1.2.10
Wireman - Hand Tools - Wire Joints - Soldering

Identification of simple types- screws, nuts and bolts, chassis, clamps, rivets
etc
Objectives: At the end of this exercise you shall be able to
• identify the screws by their thread and head
• identify the bolts and nuts by their thread head shop and size
• identify the chasis clamps and riverts.

Requirements
Tools and Instruments/equipment Materials
• Measuring streel rule - 1 No. • Various types of screws
• Outside micrometer - 1 No. • Various types of bolts
• Various types of riverts

PROCEDURE
TASK 1: Identify the screws by their thread and head shop
1 Collect all types of screws
2 Separate the screws by their thread and head shape
3 Take the screws and measure their length and diameter
of thread.
4 Identify the type of screws from their head shape.
(Hexagonal, square round). (Fig 1)

__________

TASK 2: Identify the bolts and nuts by their threads and head shape
1 Collect all types of bolts width nuts.
2 Separate the bolts by their heads. (Fig 2)
3 Measure the diameter of nuts inner and outer and note
down. Inner -------- mm. Outer ------------- mm.
4 Measure the length and diameter of bolt by steel rule
and note down.

__________

TASK 3: Identify the chasis clamp and riverts

1 Collect the chasis clamp and rivert.
2 Separate the clamps and riverts. (Fig 3)
3 Measure the size of clamps and rivert their size by
steel rule.
4 Note the size clamp and rivert ------------ mm.
5 Get it check with your instructor.

27
Hexagonal nuts Hexagonal nuts are available in different thicknesses. Thin
nuts are used as lock-nuts. (Fig 2)
This is the most commonly used type of nut in structural
and machine tool construction. (Fig 1)

Square nut
Square bolts are provided with square nuts. In bolts for
coaches mostly square nuts are used. (Fig 3)

__________

28 Power: Wireman (NSQF Level - 4) - Exercise 1.2.10

Power Exercise 1.2.11
Wireman - Hand Tools - Wire Joints - Soldering

Use, care and maintenance of various hand tools. Familiarization with signs
and symbols of Electrical accessories
Objectives: At the end of this exercise you shall be able to
• select proper tools for specific uses
• write care and maintenance procedures with precaution for each tool
• perform care and maintenance for tools, while using
• identify the signs and symbols of electrical accessories.

Requirements
Tools and Instruments/equipment • Firmer chisel 12 mm - 1 No.
• Tenon saw 300 mm - 1 No.
• Combination plier - 150 mm - 1 No.
• Plumb bob - 1 No.
• Flat nose plier 150 mm - 1 No.
• Centre punch 50 mm - 1 No.
• Diagonal cutting plier 150 mm - 1 No.
• Cold chisel - 1 No.
• Round nose plier 150 mm - 1 No.
• Hacksaw frame with blade - 1 No.
• Screw driver 150 mm - 1 No.
• Portable electric drilling machine - 1 No.
• Star-headed screw driver 100 mm - 1 No.
• Electrical accessories signs and
• Neon tester - 1 No.
symbols chart - 1 No.
• Electrician's knife 100 mm - 1 No.
• Try square 150 mm - 1 No.

PROCEDURE
TASK 1: Select the proper tools for specific uses and write their care and maintenance
1 Identify proper tools for specific uses from Fig 1 to 16 ,
2 Write the uses of each selected tool and the care and
maintenance to be followed while handling in Table 1.
Table 1
Tool Uses/Operation Care, Maintenance with
used for Precautions in operation
1 Combination pliers (Fig 1)

29
 Tool Uses/Operation Care, Maintenance with
used for Precautions in operation

2 Pliers - round nose

3 Pliers - flat nose

4 Pliers - diagonal cutting

30 Power: Wireman (NSQF Level - 4) - Exercise 1.2.11

 Tool Uses/Operation Care, Maintenance with
used for Precautions in operation
5 Screwdriver

6 Screwdriver (Star)

7 Electrician's knife

8 Neon tester

Power: Wireman (NSQF Level - 4) - Exercise 1.2.11 31

 Tool Uses/Operation Care, Maintenance with
used for Precautions in operation

9 Portable electric drilling machine

10 Hacksaw

11 Cold chisel

12 Tenon saw

32 Power: Wireman (NSQF Level - 4) - Exercise 1.2.11

 Tool Uses/Operation Care, Maintenance with
used for Precautions in operation
13 Try square

14 Firmer chisel

15 Centre punch

Power: Wireman (NSQF Level - 4) - Exercise 1.2.11 33

 Tool Uses/Operation Care, Maintenance with
used for Precautions in operation

16 Plumb bob

4 Get it checked by your instructor.

__________

TASK 2: Perform care and maintenance of tools

Prevent rust formation If you find mushrooms report to your instructor to enable
him to remove the mushroom through grinding.
1 Inspect all the tools. If the tools are rusted, use fine
emery paper to remove the rust. Reshaping the screwdriver tip
While removing rust keep your hands safe from 8 Check the tips of the flat tipped screwdrivers. If the tip
sharp edges. Do not use emery paper on steel is blunt or disfigured report to the instructor.
rule or tape.
Observe how the screwdriver tip is ground to
2 Apply a thin coat of oil over the surface of the rusted form a perfect cornered tip for effective use.
tool and clean with a cotton cloth.
Sharpen and set the saw-teeth
A hammer should not have any trace of oil on
9 Check the teeth of the Tenon saw.
its striking surface.
If the saw-teeth are blunt, report to your
3 Check and lubricate tools for easy movement of the
instructor. Observe how the saw-teeth is filed
jaws of the pliers, blades of knives, jaws of wrench,
to make the saw-teeth sharp.
pincers, gears of the hand drilling machine.
10 Check the saw-teeth setting.
4 Apply a drop of oil on the hinged/geared surface, if the
movement is hard. The teeth of the Tenon saw should be set to be
able to alternately remove dust while sawing.
5 Activate the jaws and gears till the muck/grim in the
If the setting is not proper report to the
surfaces are cleaned
instructor.
6 Apply a drop of oil again and clean the tools with a
11 Check how the teeth are set by a saw-setter.
cotton cloth.
Remove the mushroom
7 Check the cold chisel and the hammer's striking face
for mushrooms.

34 Power: Wireman (NSQF Level - 4) - Exercise 1.2.11

TASK 3: Identify the signs and symbols of electrical accessories
1 Read and interpret the symbols of electrical acessories 2 Draw the symbols against each electrical accessories
used in wiring diagram Table - 2. given in Table - 2.

Table - 2
Sl.No Description Symbols used in the circuit Symbols used in layout

1 One-way switch, single pole

2 One-way switch, two poles

3 One-way switch, three poles

4 Two-way switch

5 Intermediate switch

6 Push-button or bell-push

7 Socket outlets, 6A

8 Socket outles, 16A

9 Fuse

Power: Wireman (NSQF Level - 4) - Exercise 1.2.11 35

Sl.No Description Symbols used in the circuit Symbols used in layout
10 Bell

11 Buzzer

12 Earth point

13 Circuit breaker

14 Terminal strip

15 Link (closed)

16 Plug and socket (male and female)

17 Ceiling rose

18 Siren

36 Power: Wireman (NSQF Level - 4) - Exercise 1.2.11

Power Exercise 1.2.12
Wireman - Hand Tools - Wire Joints - Soldering

Practice in using cutting pliers, screw drivers etc. skinning the cables, and
joint practice on single strand
Objectives: At the end of this exercise you shall be able to
• skin the cable insulation using the electrician's knife
• skin the cable insulation using manual stripper
• skin the cable insulation using auto-stripper
• practice on making a straight twist joint in single strand conductor.

Requirements
Tools and Instruments/equipment Materials
• Electrician tool kit - 1 No. • Aluminium cables of the following sizes:
• Electrician's knife 100 mm blade - 1 No. • PVC single strand cable
• Wire stripper, manual 200 mm - 1 No. 1/1.4, 1.5 sq. mm - 3 m.
• Wire stripper auto–eject 150 mm - 1 No. • PVC single strand aluminium cable
• Combination pliers 150 or 200 mm - 1 No. 1/1.8, 2.5sq. mm - 3 m.
• Steel rule 300 mm - 1 No. • Cotton waste - as reqd.
• Diagonal cutter or side cutting pliers • Emery sheet '00' - 1 No.
150 mm - 1 No.

PROCEDURE
TASK 1: Skinning cable insulation using the electrician's knife
1 Mark the length of the 1.5 sq. mm cable at 400 mm 6 Remove the insulation of the cable for about 10 mm at
from its end. the ends using a knife. (Fig 3) Keep the knife blade at
an angle less than 20° to the cable.
2 Cut the cable using combination pliers on the mark.
7 Check for nicking over the conductor. Also check if the
3 Mark the length of insulation to be skinned from either
cable is not shaved.
end. (Fig 1)

8 Clean the surface of the bare conductor and show it to

4 Check the sharpness of the knife blade and re-sharpen,
the instructor.
if necessary.
9 Cut the cable at 12 mm from either end using a
5 Slice the insulation at an angle of approximately 15° to
combination plier.
avoid cutting into the conductor. (Fig 2)
9 Repeat steps No.5 to No.8, until the cable is of 350
mm length
11 Mark the insulation that is to be removed as in Fig 4
and repeat steps 6 and 7.

12 Repeat the skinning of cable insulation of 2.5 sq. mm,

Use an oilstone to sharpen the knife's blade. 14/0.2 mm, 23/0.2 mm, 48/0.2 mm, 80/0.2 mm and
128/0.2 mm flexible cables.
Visible thickness at the cutting edge of the
knife blade indicates a blunt edge. In the case The length of the cable after skinning both the
of a sharp edge, the thickness or end will not ends shall be suitable for termination using
be visible. crimping and screw.

37
 The length of the finished skinned cable should In the case of flexible stranded cables to
be 300, 500, 600, 800, 1000 mm. These cable ensure that the strands are not cut is essental.
pieces are to be used for later exercises.
__________
TASK 2: Skinning cable insulation using a manual stripper
1 Mark the length of the cable to be trimmed off. 7 Pull the stripper to remove the insulation. (Fig 7)
2 Trim the cable at the mark using a combination plier
diagonal cutter.
3 Straighten the ends where the insulation is to be
skinned.
4 Mark the point where the insulation is to be skinned.
5 Adjust the jaws of the manual stripper and set them to
suit the cable conductor. (Fig 5)

Partially cut insulation can be removed only

with more force. Excessive force, indicates
improper cutting of insulation.
8 Repeat the skinning of insulation for 10 mm to develop
skill in the use of the wire stripper.
9 Remove insulation to the required extent at the ends
as per Fig 8.

6 Set the jaws at the mark, press the handle of the

stripper and turn to cut the insulation. (Fig 6)

10 Be caeful with flexible cables to ensure that you do not

nick even a single strand.
Precautions:
• When using this tool, make sure that it is
correctly adjusted before trying to strip the
insulation from the cable so that it does not
damage the conductor.
Do not nick the conductor. For better practice
try on a small waste piece. • Do not use this tool to cut metallic
conductors.

__________

TASK 3: Skinning cable insulations using auto-stripper

1 Mark the length of the insulation to be removed from
the ends.
2 Straighten the cable ends.
3 Select a proper set of stripper.
4 Locate the jaws of the stripper exactly on the mark.
(Fig 9 & 10)
5 Press the stripper.
Further pressing may damage the insulation
from the cable end, that is also to be removed.

38 Power: Wireman (NSQF Level - 4) - Exercise 1.2.12

 7 Repeat steps No 1 to 7 for different sizes of cables.
Precautions: While using this stripper the cable
insulation should be put in the proper slot to
avoid damage to the conductor.
Becareful while using the knife.
Always cut keeping the object to be cut away
from your body.
Knives should not be used to remove insulation
on very fine single or stranded conductors.
Knives should not be used to cut conductors.
6 Check that the cable conductor is not nicked. 8 Get it checked with your Instructor.

__________

TASK 4: Make simple (straight) twist joint in single strand conductor

1 Collect 2 pieces of 1/1.12 PVC copper cable of 0.5 m 8 Twist them tightly around each other in the opposite
length. directions.
2 Straighten the cables. Pliers can be used to just grip the crossed
conductors.
3 Mark 80 mm length on one end of each piece of the
cable. Each side should contain about 6 turns.
4 Use the knife at 20o as shown in Fig 11. Each turn of the conductor should closely fit to
the adjacent turn.
9 Cut the excess length of the conductor using side
cutters.
10 Press the sharp edge of the conductor end and smooth
it.
Soldering the joint and insulating it with tape
should be completed before putting the jointed
5 Remove the insulation from each conductor for a length cable in use.
of 50 mm. (Fig 12)
11 Show the joint to your instructor.
12 Cut the joint after leaving 30 mm cable from the joint.
(Fig 14)

Avoid nicks in the conductor.

6 Clean the ends with the help of a cotton cloth. 13 Repeat steps 3 to 9 and make at least 4 more joints
Use smooth sandpaper, if necessary, to clean for practice, using the remaining cable.
the conductor.
7 Place the conductors together, about 50 mm from the
ends. (Fig 13)

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.2.12 39

Power Exercise 1.2.13
Wireman - Hand Tools - Wire Joints - Soldering

Demonstration and Practice on bare conductors joints--such as rat tail,

Britannia, straight, Tee, Western union Joints
Objectives: At the end of this exercise you shall be able to
• make britannia straight joint in bare copper conductor
• make britannia ‘T’ (Tee) joint in bare copper conductor
• make rat tail joint in bare copper conductor.

Requirements
Tools and Instruments/equipment Materials
• Steel rule 300 mm - 1 No. • Hard drawn bare copper wire 4 mm
• Diagonal cutting plier 150 mm - 1 No. diameter 0.3 metre - 4 Nos.
• Combination plier 200 mm - 1 No. • Tinned copper wire of dia. 0.91 mm - 4 m.
• Hand vice 50 mm jaw - 1 No. • Sandpaper `0 0' - 1 sheet.
• Flat file bastard 200 mm - 1 No. • Cotton cloth 300 x 300 mm - 1 No.
• Wooden mallet 75 mm diameter. - 1 No. • HDBC wire 4 mm diameter 0.3 metre - 2 Nos.

PROCEDURE
TASK 1: Make brittannia Tee joint

(A completed britannia straight joint is in Fig 1.) 6 Form a loop of binding wire leaving one end about 250
mm at the right side of the joint. Place the binding wire
in the groove formed in between the main conductors
as in Fig 3.

1 Collect two pieces of 4 mm diameter Hard Drawn Bare

Copper (H.D.B.C) . wire, 0.3 m long.
2 Straighten the conductors using a mallet and clean it
using fine sandpaper and cotton cloth.
7 Start binding the wire tightly over the joint from position
Use the mallet to make the wires straight. The
`A' and continue till position `B'. (Fig 4)
two pieces should be free from twists over the
entire length of the joint.
3 Bend and shape of one of the conductors according to
the size in Fig 2, with the help of combination pliers.

8 Insert the free end of the wire inside the loop as in

Fig 4.
9 Grip the 250 mm loose end of the wire with a pair of
4 Collect the binding wire and straighten it without any pliers, and carefully pull it so that the loop and the free
kink. end of the wire go inside the joint.
5 Hold the two ends of the bare copper wire to be joined 10 Wrap the free end and the loose end over the conductors
in the hand vice as in Fig 2. as in Fig 1.
11 Press the ends of the binding wire to the conductors
with pliers .
40
12 Smooth the sharp edges of the protruding wire ends After completion the joint must be soldered
with a flat file. before putting it to use.
13 Repeat the above steps and make two or more joints
to get more practice.

__________
TASK 2: Make britannia straight joint
(A completed britannia `Tee' joint is in Fig 5).

8 Insert the free end of the wire inside the loop as in

Fig 8.
1 Collect two pieces of 4 mm diameter Hard Drawn Bare
copper (H.D.B.C) 0.2 m long.
2 Straighten the conductors using a mallet and clean it
with fine sandpaper and cotton cloth.
3 Bend each piece at one end for about 20 mm length at
900 as in Fig 6.

9 Grip the 250 mm loose end of the wire with a plier, and
carefully pull it so that the loop and the free end of the
wire go inside the joint.
10 Wrap the free end and the loose end over the conductors
as in Fig 1.
11 Press the ends of the binding wire to the conductors
with plier.
4 Straighten the (0.914 mm diameter.) binding wire. 12 Smooth the sharp edges of the binding wire ends with
a flat file.
5 Hold the two copper conductors to be joined with the
help of a hand vice as in Fig 6 . 13 Repeat the above procedure to make two or more joints
to get more practice.
6 Form a loop of binding wire leaving one end about 250
mm at the right side of the joint. Place the binding wire The joints need to be soldered before putting
in the groove formed between the conductors as in them into use.
Fig 7.
7 Start binding the wire tightly over the joint from position
`A' and continue till the position `B'. (Fig 7)

__________

TASK 3: Make rat-tail joint in bare copper conductor (Fig 9).

3 Clean the conductor ends with the help of cotton cloth.
4 Cross the bare wires at of 45o and at a distance of 60
mm from the cable end.
5 Tightly twist the ends as in Fig 10.

1 Collect 2 pieces of 4 mm bare copper conductor of The twist on the conductor should be uniform
0.3 m length. and close.

2 Straighten the conductors.

Power: Wireman (NSQF Level - 4) - Exercise 1.2.13 41

 7 Fold the remaining conductor back on the twists.
(Fig 9)
8 Press the ends of the conductor with the help of
combination pliers (Fig 9) to avoid sharp ends, and cut
the excess wire.
9 Repeat the steps.3 to 8 of TASK 3 for at least 4 more
joints for practice.

6 Make at least 6 twists. (Fig 11)

__________

TASK 4: Make western union joint in bare conductor

(A completed western union joint is in Fig 12.)

1 Collect two pieces of bare copper conductor of 4 mm

diameter. and 30 cm long.
2 Straighten the conductor with a mallet.
7 Wrap one conductor over the other conductor using
3 Mark the conductor as in Fig 13.
combination pliers. Make at least 5 to 6 turns as in
Fig 16.

4 Clean both the conductors with `00' grade sandpaper

to a length of 250 mm from one end.
5 Bend both the pieces of conductors at a distance of
110 mm from one end to 45o as in Fig 14.

8 Repeat the same procedure in the other end of the

conductor, but wrap the conductor in the opposite
direction.
9 Cut the surplus conductor ends with a diagonal cutter.
10 Use a mallet to mesh the ends with the straight
6 Hold the conductors in the hand vice as in Fig 15. conductor.
To avoid nicks on the conductors while 11 Smoothen the ends of the conductors with a flat file to
gripping in a hand vice, always use soft avoid sharp edges.
materials like aluminium sheets between the 12 Repeat the Western union joint with G.I. wire of diameter
jaws. 4 mm.
__________

42 Power: Wireman (NSQF Level - 4) - Exercise 1.2.13

Power Exercise 1.2.14
Wireman - Hand Tools - Wire Joints - Soldering

Practice in soldering and brazing

Objectives: At the end of this exercise you shall be able to
• solder the copper conductor joints using a soldering iron and rosin solder
• solder the lugs in copper conductor with the help of a blow lamp
• braze the joint using filler rod.
• measure the resistance by voltmeter and ammeter method
• determine the specific resistance.

Requirements
Tools and Instruments/equipment Materials
• Electrician tool kit - 1 No. • Finished simple twist joint - 1 No.
• Combination piler 200 mm - 1 No. • Sandpaper ‘OO’ grade - 9 Sq.cm
• Electric soldering iron 65W, 250V, • Resin-cored solder - 25 gms
50Hz - 1 No. • VIR or PVC copper cable 7/1.06 mm
• Flat file bastard 250 mm - 1 No. or 7/0.914 - 250 mm long - 2 pieces
• Electrician's knife 100 mm - 1 No. • Lug 30 amperes (6 mm2) - 1 No.
• Steel rule 300 mm - 1 No. • Resin flux - 10 gms.
• Diagonal cutting plier 150 mm - 1 No. • Solder stick 60/40 - 100 gms.
• Blowlamp 1 litre capacity - 1 No. • Matchbox - 1 No.
• Tongs 300 mm - 1 No. • Cotton tape or cloth - as required.
• Sheet steel tray 150 x 150 x 20 mm - 1 No. • Brass (or) filler rod - 1 No.
• Blowlamp pin - 1 No.
• Kerosene - 1 litr.

PROCEDURE
TASK 1: Solder the copper joints

(A finished soldered joint will look like Fig 1.) 2 Check the bit (Fig 3) to see whether the surface is
smooth and clean.

1 Select a 65W, 240V AC 50 Hz. soldering iron (Fig 2)

and check that the iron has no physical damage, the
body is well insulated from the element and is of the
correct voltage and power rating.

3 If found corroded, file the tip with a flat file, so that the
surface is smooth and clean. (Fig 4)

A soldering iron should show continuity

between its terminals. Insulation resistance
between the terminal and the body should not
be less than 2 megohms. Report to your
instructor in case the insulation resistance is
less than 2 megohms. Do not use the iron unless
it is cleared by your instructor.
4 Connect the soldering iron to the supply and switch it
`ON'.

43
 When the bit becomes sufficiently hot, apply a 8 Keep the soldering iron bit on the joint and heat it for
small quantity of rosin-cored solder, and tin the soldering as shown in Fig 8.
bit. (Fig 5).

9 Keep the rosin-cored solder on the wire joint and allow

it to melt as shown in Fig 9.
If the bit is not completely and evenly covered
with solder, clean and tin it again.
Never flick excess solder off the bit. The hot
solder may cause burns to someone or fall on
the work and cause a short circuit.
6 Wipe the bit gently on the cleaning pad to remove
excess solder as shown in Fig 6.

10 Melt the solder with the heat of the bit and make sure
that the solder flows freely and evenly on the joint.
11 Remove the soldering iron. use cotton cloth to wipe off
the excess solder from the surface of the joint when it
is still hot as shown in Fig 10.

7 Clean the joint to be soldered with the help of sandpaper

`0 0', grade as shown in Fig 7, and wipe the dust with
a wire brush.

12 Allow the joint to cool naturally. Do not blow air for

cooling.
A shining solder surface indicates good
soldering. Do not move the joint until the solder
solidifies.

__________

TASK 2: Solder lug to a copper conductor

(A soldered lug should look as shown in Fig 11.) 2 Clean the inner and outer surfacses of the 30 amps
cable lug using `00' grade sandpaper.
3 Put the cable lug to one end of the cable and mark the
cable according to the depth of the cable lug, as shown
in Fig 12.

1 Collect a 30 amps cable lug, copper cable 7/1.06 or 7/

0.914(6 sq.mm) of 250 mm length, blowlamp,
matchbox, cotton cloth, solder stick, tray and flux.

44 Power: Wireman (NSQF Level - 4) - Exercise 1.2.14

 A thin coating of tin should be on the stranded
cable end.
9 Apply a small quantity of flux inside the lug socket. Tin
the lug by melting the solder stick to fill the socket and
pour the molten solder in the tray.
Pouring out the molten solder from the lug
4 Add about 2 mm to the marking, remove the insulation socket a couple of times will make the tinning
from the cable (Fig 13) and clean the strands. perfect.
10 Apply some flux to the cable end and the interior of the
socket.
11 Fill the socket of the lug with molten solder. (Fig 16)

Avoid damage to the strands of the cable while

skinning. Clean the tray thoroughly. The tray
should be free from dirt and water.
5 Wrap a cloth/cotton tape on the insulation of the cable
to a length of 30 mm as shown in Fig 14, and wet it
with water.

12 Monitor the blowlamp flame on the socket, insert the

cable in the socket and hold the cable vertically as
shown in Fig 17.
Use minimum water to wet the cloth/tape. Do
not allow water to drip.
6 Light the blowlamp and let it emit a blue flame.
7 Apply a thin coat of flux to the cable end.
8 Tin the cable end by monitoring the blowlamp on the
solder stick and allowing the molten solder to fall on
the bare stranded cable end as shown in Fig 15.

13 Remove the blowlamp and firmliy hold the cable and

socket without shaking.
14 Remove the extra solder from the lug and cable by
wiping it with a piece of cotton cloth while the solder is
still hot.
15 Keep on holding the cable and lug as in Fig 17 and
allow the solder to solidify.
Do not use water to cool the lug. This will
crystallize the solder and make it weak.

__________

TASK 3: Practice on brazing on copper wire soldered joint

1 Select the finished copper joint for soldering (Fig 18). 4 Clean the surface of the joint by using a cloth.
2 Solder the wired joint of (Fig 18). 5 Heat the joint by using blow lamp untill the joint glows.
3 Scult the surface of the joint using emery cloth.

Power: Wireman (NSQF Level - 4) - Exercise 1.2.14 45

 8 Get the approval from the instructor after completely
the task.

6 Apply the copper phosphrous brazing rod filler to the

joint while continuing to heat the surface. (Fig 19)
7 Clean the brazed surface the using emery cloth to
remove any ozidation (or) resistance.

__________

46 Power: Wireman (NSQF Level - 4) - Exercise 1.2.14

Power Exercise 1.2.15
Wireman - Hand Tools - Wire Joints - Soldering

Application of Wheatstone bridge in measurement of resistance and determine

the specific resistance
Objectives: At the end of this exercise you shall be able to
• identify the terminals of a Wheatstone bridge
• complete the bridge with resistors
• operate a wheatstone bridge to get ‘Null’ deflection
• calculate the value of unknown resistance using the wheatstone bridge.

Requirements
Tools and Instruments/equipment • Resistor 10 ohm 5W - 1 No.
• Resistor 1K ohm 2W - 1 No.
• Wheatstone bridge - 1 No.
• Resistor 330K ohm 2W - 1 No.
Materials • Torch cells/battery for Wheatstone
• Resistor 2 ohm 5 W - 1 No. bridge - as reqd.
• Resistor 50 ohm 5W - 1 No.

PROCEDURE
TASK 1: Measuring an unknown resistance using Wheatstone bridge
1 Identify the ratio arm (PQ), variable resistance (S), 9 Close the switch and watch the deflection of the
sensitivity control (SC), switch (S1), galvanometer (G), galvanometer.
connecting terminal (x, xx) and battery compartment
10 Adjust the variable arm by closing the switch, to get a
of the Wheatstone bridge and correlate it with the
minimum deflection in the galvanometer. (In case the
schematic diagram in Fig 1.
galvanometer needle overshoots, reset the ratio arm.)
11 Increase the sensitivity and repeat step 10.
12 When `Null' deflection is achieved in the galvanometer,
note the value of the ratio arm and position of the
variable resistance. Enter the values in Table 1.
13 Apply the formula given below and calculate the
resistance.
Unknown resistance in ohms = ____________
Reading of ratio arm setting X value of variable resistance

P S

2 Check the battery for its condition. Q R

3 Check the values of the ratio arm. S

R Q
4 Check the minimum and maximum values of the P
variable resistance.
14 Enter the values in Table 1.
5 Connect the unknown resistor across terminals x and
xx. 15 Repeat the procedure for measuring at least four
nknown resistors and enter their respective values in
6 Set the ratio arm to the approximate value of the
Table 1.
unknown resistor.
16 Get the work approved by the instructor.
7 Set the variable resistor knob in the middle.
8 Set the sensitivity control to `Low'.

47
 Table 1
Sl.No. Type of resistor Setting of ratio arm Value of variable Resistor value in ohms
resistance = Ratio arm x value of
variable resistance

__________

TASK 2: Measuring the resistance of different metal wires having the same length and the same area of cross-
section using wheatstone bridge
1 Collect steel, Nichrome, aluminium and copper wires Conclusion
of the same gauge.
1 Write the name of the wire material which has the
2 Verify the area of the cross-section (by measuring lowest resistance.
diameter) and the length of the different metal wires,
___________________________________________
and ensure they are all the same.
2 Write the name of the wire material which has the
3 Fix the wies in the order shown in Fig 1 on the wooden
highest resistance.
board.
___________________________________________
3 Write in an order the name of the conductor metals
such that their resistance value per metre length is
ascending.
___________________________________________
___________________________________________
___________________________________________
___________________________________________
4 Find the ratio of resistance of copper, aluminium, steel
and Nichrome in the above example.
___________________________________________
4 Connect the wheatstone bridge terminals x and xx to 5 Write what you have understood from this experiment
the steel wire. about conductivity of the material.
5 Measure the resistance of the steel wire by the ___________________________________________
wheatstone bridge.
___________________________________________
6 Enter the value in Table 1 and Table 2.
6 Specific resistance of the material is indicated by the
7 Measure the diameter a line material by using Greek letter ____________ and is spelt as 'Rho'.
micrometer.
8 Repeat steps 4,5 and 6 for Nichrome, alumimium and
copper wires using the same connecting leads.
9 Include area of cross section of materials.

48 Power: Wireman (NSQF Level - 4) - Exercise 1.2.15

 Table 1
Sl.No. Conductor metal Length of metres Dia in mm. Area of cross
section in mm2

1 Steel 1

2 Nichrome 1

3 Aluminium 1

4 Copper 1

__________

TASK 3: Determine the specific resistance of steel, Nichrome, aluminium and copper

1 Enter the detail of the material of the wire, area of cross Which of the above mentioned metal is most
section length and resistance value collected from task suitable as resistance wire?
2 in Table 2.
Which of the above mentioned metal is most
2 Calculate the specific resistance of the conductor metal suitable as electrical conductor wire?
AR 4 Get it checked into your instructor.
in each case using the formula S 
L
3 Write the conclusion from the above result.
i Arrange the specific resistance of copper, steel
aluminium and Nichrome in ascending order.

Table 2

A L
R
S
Sl.No. Conductor Length Dia. in mm Area of Resistance Remarks
metal in cm 'L' cross-section value in 
in Cm2 'A' ohms 'R'

1 Steel 100 cm

2 Nichrome 100 cm

3 Aluminium 100 cm

4 Copper 100 cm

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.2.15 49

Power Exercise 1.3.16
Wireman - Basic Electrical Practice

Demonstration and identification of types of cables

Objectives: At the end of this exercise you shall be able to
• identify types of wires and cables
• verify their specifications referring to the data book.

Requirements
Tools and Instruments/equipment Materials
• Electrician's knife - 1 No. • Wires (assorted size) - as required.
• Manual wire stripper 150 mm - 1 No. • Cables (underground armoured
• Combination pliers 200 mm - 1 No. and unarmoured cable) - as required.
• Wire/ cable specification data book - 1 No.

PROCEDURE
TASK 1: Identify types of wires and cables

The instructor will arrange and provide the 4 Verify the specifications of the wires by referring with
various types of cable and wire pieces (assorted the data book.
sizes) on the table and label them with 5 Take any one cable from the table, note down its
alphabets and explain them to trainees on, how alphabet.
to identify the types of insulation, conductors,
size of wires. 6 Identify the type of cable (unarmoured and armoured
cable) and note down in Table 1.
1 Take any one wire from the table, note down its aplhabet
7 Identify the type of insulation, core and record in
in Table 1.
Table 1.
2 Identify the type of insulation, type of conductor material
8 Verify the specifications of the cable by referring with
and size of wires. Note it down in Table 1.
the data book.
3 Take at least five different types of wires and repeat
9 Repeat steps 1 to 8 for various wires and note the data
steps 1 and 2 Note down the details in Table 1.
in Table 1.

Table 1
Sl. Alphabet Type of Type of Type of cable Type of core Core
No. insulation conductor single/3/3½ size in
material Armoured Unarmoured mm

1 A

2 B

3 C

4 D

5 E

__________

50
Power Exercise 1.3.17
Wireman - Basic Electrical Practice

Demonstration and practice on using standard wire gauge and micrometer

Objectives: At the end of this exercise you shall be able to
• measure the size of wire using standard wire gauge
• measure the size of wire using micrometer.

Requirements
Tools and Instruments/equipment Materials
• Standard Wire Gauge (SWG 0-36) - 1 No. • Wires (assorted size) - as required.
• Outside Micrometer (0-25) - 1 No. • Cables (underground armoured
• Electrician's knife 100mm - 1 No. and unarmoured cable) - as required.
• Manual wire stripper 150 mm - 1 No. • Wire/ cable specification data book - 1 No.
• Combination pliers 200 mm - 1 No.

PROCEDURE
TASK 1: Measuring the wire sizes by SWG in gauge number
1 Skin the insulation of the cable. 5 Read the marking at the slot, Fig 2. It gives the wire
size in SWG. The other side will give you the diameter.
Exercise care to prevent from nicking.
of the wire in mm.
2 Clean the surface of the wire with a cotton cloth.
Remove insulation particles and any adhesive coating
from the surface of the conductor.
Do not use abrasives to clean the conductor.
Use of abrasive material, reduces the size of
the conductor.
3 Straighten the end of the conductor to be measured.
Do not straighten conductors by directly using
hand tools on them.
4 Insert the conductor in the slot of the wire gauge and
determine its close fit. (Fig 1) 6 Refer to the conversion table (Table 2) to get the size
of the conductor in the standard wire gauge.
7 Record the measured size in Table 1.

Table 1
Sl. Name of the Size of wire Size of
No. wie specification SWG wire mm

__________

51
TASK 2: Measuring the wire size, using micrometer
1 Repeat steps 1-3 of TASK 1.
2 Check the micrometer for zero error by operating the
spindle.
3 Record the error value with the sign- +ve or –ve.
4 Place the cleaned, straight portion of the conductor
between the jaws (anvil and spindle) of the micrometer.
(Fig 3)
5 Close the spindle of the micrometer by turning the 7 Repeat the steps to find the measurement for the given
thimble. cables.
Use the ratchet drive to avoid overtightening. 8 Get it checked by your instructor.
6 Read and record the diameter in Table 1 after computing
zero error.
Table 2
Conversion table : SWG to inch/mm
No. Inch mm No. Inch mm
7/0 0.500 12.7 23 0.024 0.61
6/0 0.464 11.38 24 0.022 0.56
5/0 0.432 10.92 25 0.020 0.51
4/0 0.400 10.16 26 0.018 0.46
3/0 0.372 9.44 27 0.0164 0.42
2/0 0.348 8.83 28 0.0148 0.38
0 0.324 8.23 29 0.0136 0.34
1 0.300 7.62 30 0.0124 0.31
2 0.276 7.01 31 0.0116 0.29
3 0.252 6.40 32 0.0108 0.27
4 0.232 5.89 33 0.0100 0.25
5 0.212 5.38 34 0.0092 0.23
6 0.192 4.88 35 0.0084 0.21
7 0.176 4.47 36 0.0076 0.19
8 0.160 4.06 37 0.0068 0.17
9 0.144 3.66 38 0.0060 0.15
10 0.128 3.25 39 0.0052 0.13
11 0.116 2.95 40 0.0048 0.12
12 0.104 2.64 41 0.0044 0.11
13 0.092 2.34 42 0.0040 0.10
14 0.080 2.03 43 0.0036 0.09
15 0.072 1.83 44 0.0032 0.08
16 0.064 1.63 45 0.0028 0.07
17 0.056 1.42 46 0.0024 0.06
18 0.048 1.22 47 0.0020 0.05
19 0.040 1.02 48 0.0016 0.04
20 0.036 0.91 49 0.0012 0.03
21 0.032 0.81 50 0.0010 0.02
22 0.028 0.71 _ _ _ _ _ _ _ _ _ _

52 Power: Wireman (NSQF Level - 4) - Exercise 1.3.17

Power Exercise 1.3.18
Wireman - Basic Electrical Practice

Practice on crimping thimbles, Lugs

Objectives: At the end of this exercise you shall be able to
• skin the cable end
• select the pressure terminal (compression connector) that suits the size of the wire and that of the terminal
• select the pressure pliers that match the size of the pressure terminal
• use the crimping tool to crimp the thimbles and lugs at the cable end
• use an eyelet crimping plier for eyelet termination.

Requirements
Tools and Instruments/equipment • Eyelet closing pliers 200 mm with
eyelets having inner diameter
• Pressure pliers 200 mm - 1 No.
of 3,4,5,6,7 mm. - 1 No.
• Electrician's knife 100 mm - 1 No.
• Wire stripper (manual) 200 mm - 1 No. Materials
• Combination pliers 200 mm - 1 No. • Crimping eyelet, eye hole dia. 6 mm - 12 Nos.
• Crimping pliers 150/200 mm - 1 No. • Crimping ferrule 4 mm,10 mm long - 6 Nos.
• Wire stripper auto-eject 200 mm - 1 No. • Crimping spade lug 6A - 6 Nos.
• Steel rule 300 mm - 1 No. • Crimping spade lug 10A - 6 Nos.
• Side cutting pliers 200 mm - 1 No. • Crimping spade lug 16A - 2 Nos.
• Conducting paste - 1 tube

PROCEDURE
TASK 1: Crimping of lug thimble and connector
1 Collect the cable (fine multi-strand copper conductor).
2 Collect the spade connector suitable for the wire
thickness and terminal size of 6 mm diameter
(Fig 1,2 & 3).

3 Select the wire stripper blade size to match the wires

thickness (auto-eject) or adjust the jaws of the stripper.
(Fig 4)

4 Strip a length of insulation that suits the terminal size

(spade connector) (Fig 5)
Be sure not to cut or damage the wire core.

53
 Do not strip too much insulation. (Fig 10)

Adjust the length of the wire so that it does not

interfere with the terminal hole. (Fig 11)
5 Twist the strands of the wire lightly in the direction of
strands. (Fig 6)

9 Apply light pressure to create a light impression on

the compression connector.
10 Check whether the press is located in the middle of
6 Select the crimping pliers that matches the terminal the band of compression connector and, if necessary,
size. make final adjustment.

7 Clamp the spade connector with the crimping pliers 11 Apply sufficient pressure in the handle to press the
with the matching position of jaws. compression connector fully, as shown in Fig 12.

8 Insert the wire far enough in the compression connector.

(Fig 7)

12 Check whether the prepared compression/crimping joint

is firm by pulling the cable and compression connector.
Do not clamp the insulation in the terminal.
(Fig 8) 13 Repeat the crimping of compression in the connectors
of various sizes of copper and aluminium conductors
of different lengths.
Trim the appropriate length of the skinned
cable ends to suit the compression connectors.
The types of compression connectors to be
fixed at the cable ends will be as prescribed
by your instructor. Fig 2 shows the eyelet lug
Strands must not stick out of the connector.
compression connected/crimped on to the
(Fig 9)
flexible cable.

__________

54 Power: Wireman (NSQF Level - 4) - Exercise 1.3.18

TASK 3: Crimping an eyelet
1 Collect the multi-strand cable.
2 Split the number of strands into two equal parts and
twist them. (Fig 13a)
3 Collect the eyelet. (Fig 13b)
4 Fix the eyelet by placing the eyelet between the
grouped strands close to the insulation and twist the
free ends of the strands as shown in Fig 13c.

5 Trim the excess length of the multi-strand wire after

closing the eyelet using side-cutting pliers.
6 Repeat the exercise with different sizes of eyelets for
cable end termination.
7 Get it checked by your instructor.

The eyelet is then pressed on to the wire end

by the two formers of the eyelet closing pliers.
(Fig 14)

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.3.18 55

Power Exercise 1.3.19
Wireman - Basic Electrical Practice

Examination and checking of cables and conductors and verification of

materials according to the span
Objectives: At the end of this exercise you shall be able to
• check the varaious types of cable and conductor as per specification
• verify the cable materials according to the span.

Requirements
Tools and Instruments/equipment Materials
• Standard wire gauge (SWG 0-36) - 1 No. • Wires (assorted size) - as avl.
• Micrometer (0-25 mm) - 1 No. • Cables (assorted types) - as avl.
• Electrician knife - 1 No. • Wire/cable specification data book - 1 No.
• Manual wile stipper 150 mm - 1 No.
• Combination plier 200 mm - 1 No.

PROCEDURE
TASK 1: Examine and check the various types of cable and conductors

The instructor will arrange and provide the 3 Verify the specification of the wires by referring with
various types of cable and label them with the data book.
alphabets and explain them to trainees on how 4 Take any one cable from table note down its alphabet.
to identify the types of insulation and
conductors, size of wires. Demonstrate how to 5 Identify the type of insulation, core and record in
examine, check and measure. Table 1.

1 Take any one wire from the table, note down its alphabet 6 Verify the specifications of cable by referring with the
in Table 1. data book.

2 Identify the type of insulation, type of conductor material 7 Repeat the steps 1 to 6 for various wires and cables
and measure the size of wires. Note it down the details and note the data in Table 1.
in Table 1.
Table 1
Sl.No. Alphabet Type of Insulation Types of Conductor Type of care Core size
material 1/2/3/4 in mm/swg
1 A
2 B
3 C
4 D
5 E

__________

TASK 2: Verify the conductor for materials according of the span

Instructor will arrange and provide the various 1 Take 2 mtrs length of 1.5 sqmm copper wire, aluminium
types of conductor materials such as copper, wire and 1.5 sqm G.I. wire.
aluminium, G.I., silver which are possible and 2 Inject the current up to 10 Amps through the conductors
label them with alphabeets and explain to and measure the drop voltage across the 2 mtr length
trainees on conductovity and specific resistance and record in Table 2.
of each conductor materials. Demonstrate
voltage drop and powerloss according to load 3 Take 1 mtr. length of 1.5 sqmm copper wire aluminium
current and span- wire and G.I. wire.

56
4 Inject the current upto 10 Amps through the conductors 6 Find that the voltage drop and power loss increase while
and measure the drop voltage across the 1 mtr length increasing the span for some conductor material.
and record in table 2.
7 Find that the voltage drop and power loss increases
5 Find out the power loss V x I and record in Table 2. according to the specific resistivity of conductor
material.

Table 2
Sl.No. Alphabet Conductor Electrical P.D across Power loss P.D. across Power loss
material Resistivity 1mtr length across 1mtr 2mtr across 2mtr
length length length
1 A Copper 16.9 x 10-7
 cm
2 B Aluminium 26.7 x 10-7
 cm
3 C G.I. 97.1 x 10-7
 cm
4 D Silver 15.5 x 10-7
 cm
5 E Gold 22.0 x 10-7
 cm

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.3.19 57

Power Exercise 1.3.20
Wireman - Basic Electrical Practice

Verification of Ohm’s Law

Objectives: At the end of this exercise you shall be able to
• verify the relation between voltage and current when resistance is constant
• verify the relation between current and resistance when keeping voltage is constant.

Requirements
Tools and Instruments Materials
• Screwdriver 150 mm - 1 No. • S.P.Switch, 6A, 250V - 1 No.
• MC Ammeter 0 to 500 mA - 1 No. • Resistors 10, 20, 50 Ohms 5 watts - 1 each.
• MI Ammeter 0 to 1A - 1 No. • Resistor 20 ohms,2W - 1 No.
• MC Voltmeter 0 15 V - 1 No. • Connecting leads 14/0.2 mm - 1 No.
• P.V.C. insulated copper wires of
Equipment/Machines
assorted length - 8 Nos.
• 12 Volts battery 60 AH capacity OR - 1 No.
• DC variable power supply
0 - 30 V 2 amperes - 1 No.
• Rheostat 20 ohms - 3.7A - 1 No.

PROCEDURE
TASK 1: Verify the relation between current and voltage when resistance is constant
1 Check the voltmeter from the dial marking ‘V’.
2 Check the ammeter from the dial marking ‘A’.
3 Identify the fixed and variable terminals of the rheostat.
4 Connect the circuit elements as in Fig 1.
5 Check the value of each major division and minor division
of the scales of the meters.
6 Close the switch keeping the variable rheostat at the
minimum value of output.
7 Apply different voltages by varying the rheostat arm of
the potential divider in succession across the
resistance.
8 Measure the voltage and the corresponding current from
the instruments.
9 Record the measured values in Table 1.
To avoid parallax error:
Position your eye in line with the pointer and
Conculsion
also in front level of the instrument
Write your findings and conclusion by interpreting
Position your eye to coincide with the mirror
the current and voltage.
image of the pointer in instruments having
antiparallax mirror. __________________________________________
____________________________________________

__________

58
TASK 2: Verify the relation between current and resistance: When voltage is constant and resistance is variable

1 Connect the circuit elements as in Fig 2 with 0 -1A

ammeter. Adjust V at 10 volts keep it constant.
2 Close the switch ‘S’ and measure the current and
voltage.
3 Read and record values in the given Table 2.
4 Open the switch (OFF). Change the ammeter to 0-500
mA and repeat steps 2 and 3 by replacing 10 ohm
resistance by 20 and 50 ohms.
Write your findings and conclusion by interpreting the
current and resistance.
Conculsion
__________________________________________
__________________________________________

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.3.20 59

Power Exercise 1.3.21
Wireman - Basic Electrical Practice

Verification of Kirchhoff’s Laws

Objectives: At the end of this exercise you shall be able to
• verify Kirchhoff’s current Law in two and three branch currents
• verify Kirchoff’s voltage Law with one voltage and two voltage source.

Requirements
Tools and Instruments/equipment Materials
• Trainees kit - 1 No. • Resistors 1K - 4 Nos.
• Variable DC power supply unit 0-30V/1A - 2 Nos. • Resistors 2.2K - 1 No.
• Milliammeters 0 - 500 mA - 3 Nos. • Resistors 3.3K - 1 No.
• Milliammeters 0 - 30 mA - 1 No. • Resistors 4.7K - 1 No.
• Power supply unit 0 - 30 V (PSU) - 1 No. • Lug board - 1 No.
• Toggle switch, SPST, 1amp. - 2 Nos.
• Patch cords -as required.
• SPST switch 6A, 250V -as required.

PROCEDURE
TASK 1: Verify the Kirchhoff’s current law with two branch currents

1 Connect the PSU, milliammeters, SPST switch and

resistors as illustrated in the schematic circuit and the
layout diagram as in Fig 1.
Keep the SPST and PSU in OFF position while
making circuit connections.
2 Switch ‘ON’ PSU and set output to 12 volts.
3 Simplify the circuit in Fig 1 and calculate the theoretical
total circuit current and branch currents of the circuit
for a set DC supply of 12 volts. Record values in
Table 1.
Check if the connected ammeters can measure
the calculated current. Change the meter, if
necessary.
4 Get the circuit connections checked by your instructor.
5 Switch ON SPST.
6 Measure and record the total circuit current (IT) and
branch currents IS1 and IS2 in Table 1.
7 Switch OFF the SPST.
8 Set the output of the PSU to 9 volts.
9 Calculate the theoretical circuit currents for the set
supply voltage of 9V.
10 Record values in Table 1.
11 Repeat steps 4 and 6.
12 Switch OFF SPST and PSU.
13 Write Kirchhoff’s current equations for the nodes P and
Q.
14 Verify the equation substituting the measured current 15 Get the readings and equations checked by your
values. instructor.

60
 Table 1
Set Calculated values od circuit current Measured values of circuit currents
circuit
voltage Total circuit IB1 IB2 Total circuit IB1 IB2
current (IT) current (IT)
IT = IB1 + IB2 IT = IB1 + IB2

12V

9V

__________

TASK 2: Verify the Kirchhoff’s current Law with three branch currents
1 Make circuit connections on the lug board as per the 2 Get the wired circuit checked by your instructor.
schematic circuit in Fig 2.
3 With the SPST in OFF position, set the output of PSU
to 12 volts.
4 Switch ON the SPST switch. Measure and record
currents IT, IB1, IB2 and IB3 in Table 2.
5 Switch OFF SPST and PSU.
6 Write Kirchhoff’s current equations at nodes P and Q.
Verify the equation using measured current values.
7 Get the readings and equations checked by your
instructor.
8 Record your findings and conclusions after verifying
the recorded and calculated values and check if it is
same as per the theoretical conclusions.
Conculsion
Write your findings and conclusion by interpreting
the current and voltage.
Make it a practice to keep the SPST and PSU __________________________________________
switches in the OFF position while making ____________________________________________
circuit connections.

Table 2
Set circuit Total circuit Branch currents
voltage current (IT)
IT = IB1 + IB2 + IB3 IB1 IB2 IB3

12V

__________

TASK 3: Verify the Kirchhoff’s voltage Law with one voltage source
1 Measure and record in Table 3, values of resistors R4, 5 Switch ON PSU and set output to 12V. Switch ON
R5 and R6 soldered on the lug board. SPST. Following the voltage polarities marked across
the resistors, measure and record the drop voltage
2 Make the circuit connections as shown in Fig 3.
across resistors R4, R5 and R6 in Table 3.
3 Mark the polarity of the voltage drops across resistors
6 Switch OFF SPST and PSU.
R4, R5 and R6 in the copy of Fig 3.
4 Get the circuit connections and polarities marked and
checked by your instructor.

Power: Wireman (NSQF Level - 4) - Exercise 1.3.21 61

 7 Write Kirchhoff’s loop equations for the closed paths
ac-d-b-a, a-e-f-b-a and c-e-f-d-c. Substitute the voltage
readings recorded in Table 3 in the equations for
verification.
8 Get your readings and equations checked by your
instructor.

Table 3
Set circuit Measured values of Voltage measured across
voltage
R4 R5 R6 VR4 VR5 VR6

__________
TASK 4: Verify the Kirchhoff’s voltage Law with two voltage sources
1 Modify the circuit connections made in TASK 3, to obtain 3 Set the output of PSU-1 to 12 volts and PSU-2 to 6
a circuit as shown in Fig 4. volts.
Keep both the PSU’s and the two SPST’s in 4 Switch ON both SPSTs. Following the voltage polarities
the OFF position while making circuit marked across the resistors, measure and record the
connections. voltage drop across the resistors R4, R5 and R6 in
Table 4.
2 Mark the polarity of the voltage drops across the
resistors R4, R5 and R6 in the copy of Fig 4. Note: While measuring voltage across resistors,
if the meter deflects below zero, recheck the
polarity marked at step 2 and repeat step 4.
5 Switch OFF the SPSTs and PSUs.
6 Write Kirchhoff’s voltage equations for the closed paths
a-c-d-b-a, a-e-f-b-a and c-e-f-d-c.
7 Get your readings and equations checked by your
instructor.
8 Record your findings and conclusion after verifying the
recorded and calculated values and check if it is same
as per the theoretical conclusions.

Table 4
Set output of Set output of Voltage measured across
RPSU 1 RPSU 2
VR4 VR5 VR6

__________

62 Power: Wireman (NSQF Level - 4) - Exercise 1.3.21

Power Exercise 1.3.22
Wireman - Basic Electrical Practice

Verification of laws of series and parallel circuits

Objectives: At the end of this exercise you shall be able to
• verify the laws of series circuits
• verify the laws of parallel circuits.

Requirements
Tools and Instruments Equipment/ Machines
• Ammeter MC 0-500 mA - 3 Nos. • DC source, 0 - 6V/30AH (battery),
• Rheostat - 100 ohms, 1A - 1 No. Battery 12V, 90AH - 1 No. OR DC 0-30V
• Voltmeter MC 0-15V - 1 No. variable voltage supply source with
• Multimeter - 1 No. current limiting facility 0-1 ampere - 1 No.
• Rheostat 0 - 25 ohm, 2A - 2 Nos.
Materials
• Potentiometer 60 ohm, 1A - 1 No.
• Rheostat 0 - 300 ohm, 2A - 2 Nos. • Switch SPST 6A 250V - 1 No.
• Rheostat 0 - 10 ohm,5A - 2 Nos. • Resistor 10 ohm 1 W - 2 Nos.
• Resistor 20, 30, 40 & 60 ohm 1 W - 1 No. each
• Connecting cables - as required.

PROCEDURE
TASK 1: Verify the Laws of series circuits
1 Construct/ assemble the circuit as in Fig 1. 5 Switch OFF the supply. Reconnect the voltmeter and
(R1 = 10 , R2 = 20 , R3 = 10 ) ammeter as in Fig 3 and measure the voltage (V2) and
current (I2) in R2.

2 Close the switch ‘S’, measure the current (I) and voltage
(V). 6 Draw the circuit diagram showing the position of A and
3 Enter the measured value in Table 1. V in the circuit to measure the current (I3) and voltage
(V3) across R3.
4 Switch OFF the supply. Reconnect the ammeter and
voltmeter as in Fig 2 and measure voltage (V1) and 7 Connect and measure the I3 and V3 across R3.
current I1 through R1. 8 Enter the measured values in Table 1.
9 Record the relationship between I1, I2, I3 and I.
__________________________________________
__________________________________________
10 Write down the mathematical form of current law of a
series circuit.
__________________________________________
__________________________________________
__________________________________________

63
11 Record the relationship between V1, V2, V3 and V. 14 Record the relationship between R and R1, R2, R3.
__________________________________________ __________________________________________
__________________________________________ __________________________________________
__________________________________________ __________________________________________
12 Write down the mathematical form of voltage law of a 15 Write down the mathematical form of resistance law of
series circuit. a series circuit.
V= R=
13 Calculate resistance from the measured values, record 16 Get it checked by the instructor
the results with the values indicated on the resistors.
Table 1
Values Total R1=10 Ohm R2=20 Ohm R3=10 Ohm

Current I= I1 = I2 = I3 =

Voltage V= V1 = V2 = V3 =

Resistance R = _____ = R1 = _____ = R2 = ______ = R3 = ______ =

__________
TASK 2: Verify the Laws of parallel circuits
1 Use an Ohm meter to set the values of a rheostat or
resistor R1 = 40 ohms, R2 = 60 ohms and R3 = 30 ohms.
While using multimeter to measure resistance
values see that the supply is OFF and the supply
source is disconnected from the circuit.
2 Connect the resistors (Rheostats) in parallel with the
switch S, ammeter A, voltmeter V and battery B as in
Fig 4 and measure the current Is and Vs. Record the
valuesin Table 2.
3 Get it checked by the instructor.
Table 2 Measured Value of RT = ----------Ohms
1 V
Sl.No. R1 R2 R3 Calculated R  IS VS
T 1 1 1 R  S

  T I
R1 R2 R3 S

4 Measure the voltages VS, V1 , V2 and V3 and record 6 Measure the currents IS, I1, I2 and I3 and record them in
them in Table 3. Table 3.
5 Calculate the current through each resistor taking into 7 Compare the calculated values with the measured
consideration VS, applying Ohm's law and enter the values. Record your observation. _______________
values in Table 3.
__________________________________________

64 Power: Wireman (NSQF Level - 4) - Exercise 1.3.22

 Table 3
Calculated current value Measured current value
Vs V1 Measured V2 Measured V3 Measured
Value Value Value
IS I1 I2 I3 IS I1 I2 I3

8 Calculate the value of total resistance RT, from the above

measured values. 1
R 
T 1 1 1
9 Compare the measured and calculated values of total Total Resistance  
resistance RT. R1 R2 R3
Verification Conclusion
Current Characteristics IS = I1 + I2 + I3 __________________________________________
Voltage Characteristics VS = V1 = V2 = V3 __________________________________________
10 Get the work checked by the instructor.
__________

Power: Wireman (NSQF Level - 4) - Exercise 1.3.22 65

Power Exercise 1.3.23
Wireman - Basic Electrical Practice

Verification of open circuit and closed circuit network

Objectives: At the end of this exercise you shall be able to
• examine the effects of short circuited resistors in series circuits
• analyse the effects of open circuited resistors in series circuits
• analyse the effects of open and short circuted resistor in parallel circuits.

Requirements
Tools and Instruments/equipment Materials
• Screwdriver 150 mm - 1 No. • Resistors 2K, 1 Watt - 3 Nos.
• Voltmeter MC 0-15V - 1 No. • Connecting leads - as required
(Sensitivity 20K Ù/V) • Switch 6A 250V - 2 Nos.
• Voltmeter 0 - 15V MC - 1 No. Resistors carbon composition
• Ammeter 0 - 500mA - 1 No. • 62 k/¼W 5% - 1 No.
• Multimeter - 1 No.
• 33 k/¼W 5% - 1 No.
• Rheostat 100/120 Ù, 300 Ù,1A - 1 No.
• DC voltage source variable 0-15V, • 22 k/¼W 5% - 1 No.
1 amp or Battery lead acid 12V, 60AH - 1 No. • 220 k/¼W 5% - 1 No.
• 330 k/½W 5% - 1 No.
• 470 k/½W 5% - 1 No.

PROCEDURE
TASK 1: Examine the effects of short and open circuitated resistors in series circuits

1 Calculate the nominal values for the voltages VA, VB 3 Repeat steps 3 and 4 for each resistor in turn.
and VC and record them in Table 1 as in Fig 1.
4 Consider now removing R1, calculate and record the
resulting voltages at A, B and C.
5 Enter the calculated values in the fourth column of
Table 1 under the heading `Fault conditions'.
6 Repeat this for each resistor in turn.
Note: Only one fault is simulated.
7 Verify your calculations in steps 3 and 6 by connecting
a piece of wire across each resistor in turn, simulating
a short circuit across that resistor, and then removing
each resistor, simulating an open at the location.
8 Measure voltage for each fault condition and be sure to
check consistency with the calculated values.
9 Record all measured data in the corresponding columns
of Table 1.
10 Analyse the readings in healthy condition (normal
condition) and faulty (OC and SC) condition and record
Note: All voltages are with respect to ground.
the findings.
Considering resistor R1 as shorted, calculate
11 Get the work checked by your instructor.
and record the resulting voltages at A, B and
C, if this were to occur.
2 Enter the calculated values in the first column of
Table 1 under the heading `Fault conditions'.

66
 Table 1
Fault conditions

Voltages Nominal R1 S/C R2 S/C R3 S/C R1 O/C R2 O/C R3 O/C

Value Cal Meas Cal Meas Cal Meas Cal Meas Cal Meas Cal Meas

VA

VB

VC

Cal - Calculated S/C - Short circuited

Meas - Measured O/C - Open circuited
__________
TASK 2: Analyse the effect of short and open circuited resistors in parallel circuits
1 Calculate the nominal values for the currents I, I1 and 5 Consider a shorted R1. Estimate and record the
I23, I2 and I3 for the circuit in Fig 2 and record them in resulting currents if this were to occur. Enter the
Table 2. calculated values in the first column in Table 1 under
the heading `Short resistor'.
2 Construct the circuit (Fig 2) and adjust RS, source
voltage series resistor, to a value that produces 12 volts 6 Repeat step 5 for each resistor in turn.
across the parallel set of resistors.
7 Now consider removing R1. Calculate and record the
resulting currents if this were to occur. Enter the
calculated values in the last column in Table 2 under
the heading `Open resistor'.
8 Repeat step 7 for each resistor in turn.
Only one fault is simulated.
9 Verify the calculations in steps 5 and 6 by connecting
a piece of wire across each resistor in turn to simulate
a short circuit across that resistor. Measure and record
3 Set the current limit to 100mA, if the DC power supply
the current for each fault condition in Table 3.
with current limiting feature is used as Vs. Omit the
series resistor RS. (Fig 3) 10 Check the measured value of current consistency with
the calculated values in Table 2.
11 Verify the calculation in steps 7 and 8 by removing
each resistor in turn to simulate an open circuit at that
location.
12 Measure and record the current for each fault condition
in Table 3.
13 Check for the measured value of currents consistency
with the calculated values in Table 3.
4 Measure and record the values of currents (I, I1, I23, I2,
14 Analyse the readings in healthy condition (normal) and
and I3). (Use Multimeter DC milliamperes range).
faulty (OC & SC) condition and record the findings.
Record them in the 'nominal' column in Table 3.
15 Get it checked and approved by the instructor.

Power: Wireman (NSQF Level - 4) - Exercise 1.3.23 67

 Table 2
Calculated value of current

Currents Nominal Short resistor Open resistor

R1 R2 R3 R1 R2 R3

I1

I23

I2

I3

Table 3
Measured value of current

Currents Nominal Short resistor Open resistor

R1 R2 R3 R1 R2 R3

I1

I23

I2

I3

__________

68 Power: Wireman (NSQF Level - 4) - Exercise 1.3.23

Power Exercise 1.3.24
Wireman - Basic Electrical Practice

Measuring unknown resistance using Wheatstone bridge, voltage drop method

Objectives: At the end of this exercise you shall be able to
• determine unknown high resistance by voltage drop method
• test unknown low resistance by voltage drop method.

Requirements
Tools and Instruments/equipment • DC power supply unit 0-30V (RPS) - 1 No.
• Cutting plier 150 mm - 1 No. Materials
• Screwdriver 100 mm - 1 No.
• Resistor high value - 2 Nos.
• Ammeter MC 0-500 mA - 1 No.
• Resistor low value - 2 Nos.
• Multimeter - 1 No.

Measurement of unknown resistance by wheatstone bridge is already explained in Ex: 1.2.15

PROCEDURE
TASK 1: Measure the high value resistance by voltage drop method

1 Construct the circuit as diagram as in Fig 1 and connect 5 Replace with another high value resistor and repeat
the high value resistor. step 3.
The true value and the measured value of R
will be equal if we provide “0Ù resistance”
ammeter and infinite voltmeter resistance.

Table 1
Sl.No. V I V reading
R 
m A reading

2 Switch ON power supply and adjust the DC volt to 30V. 1

3 Note the current and record it in Table 1.
2
4 Verify the voltage value by using when at the piece.

__________

TASK 2: Measure low value resistance by voltage drop method

1 Costruct the circuit as in Fig 2 and connect the low Table 2
value resistor.
Sl.No. V I V reading
R 
m A reading

The true value and measured value of R will

be equal if we provide “0Ù resistance”
2 Repeat step 2 in TASK 1. ammeter and infinite voltmeter resistor.
3 Record the current and voltage in Table 2. 4 Write your conclusion _________________________.
5 Verify the value by using wheat stone bridge method.
6 Get the work approved by the instructor.
__________

69
Power Exercise 1.3.25
Wireman - Basic Electrical Practice

Experiment to demonstrate the variation of resistance of a metal with the change

in temperature
Objectives: At the end of this exercise you shall be able to
• measure cold resistance of the incandescent lamp using ohmmeter
• measure hot resistance of the incandescent lamp with supply by voltmeter and ammeter
• identify the colour of the filament with respect to the voltage variation
• determine the relation between resistance and changes in temperature.

Requirements
Tools and Instruments/equipment Materials
• Connector screwdriver 100 mm - 1 No • Double-pole switch 250V,6A - 1 No.
• MI Voltmeter 0-300V - 1 No. • Lamp 15W, 250V - 1 No.
• MC Ammeter 0-1A - 1 No. • Lamp-holder B.C.batten - 1 No.
• Ohmmeter (shunt type) - 1 No. • Candle - 1 No.
• MC Voltmeter - 5 volts or • Potentiometer 500 ohms, 0.5A - 1 No.
multimeter (digital) - 1 No. • Iron wire 0.2 mm diameter. - 2.5m.
• Connecting leads -11 Nos.
• Terminal post 16A - 2 Nos.
• Lamp 40W, 250V - 1 No.

PROCEDURE
TASK 1: Measure of cold resistance of the incandescent lamp by using ohmmeter
1 Set the ohmmeter to ‘zero’ and touch the two leads on 5 Get the circuit checked by the instructor. Keep the
the pins of the lamp. potential divider point C at B.
2 Measure the resistance of the given incandescent lamp 6 Fix the incandescent lamp in the lamp-holder and close
using ohmmeter (Fig 1). the switch.
Note: Switch OFF the supply before fixing the
lamp.
7 Adjust the potentiometer at 50 volts.
8 Close the switch and read the voltmeter and ammeter.
9 Record the values in Table 1.
10 Observe the colour of the filament and feel the
temperature on the lamp’s glass.
3 Record the value in Table 1.
Table 1
4 Form the circuit with the lamp-holder, voltmeter,
Measurement R in  Colour of
ammeter, potentiometer, D.P.S.T. switch and supply
as per the circuit diagram. (Fig 2) filament
1 Cold resistance of bulb
measured by ohmmeter
V in volts I in mA

2 50 V

3 100 V

4 150 V

5 240 V

70
11 Repeat steps 6 to 8 for 100V, 150V and 240V. Conclusion
______________________________________________
E
12 Calculate the resistance using the formula R  for ______________________________________________
I
every set of reading. ______________________________________________
13 Record the calculated values of resistance in the Table. ______________________________________________

__________

TASK 2: Determine the relation between resistance and changes in temperature using a candle
1 Make a coil of iron wire of length 0.5 m and diameter 7 The result is: I = _____ A
0.2 mm.
VD = ______ V.
2 Fix the coil between the two terminal posts mounted
on a piece of insulating board. V
3 Build the circuit according to Fig 3. Therefore, R  D
D I
8 Now, warm the coil by heating it in candle flame record
and the measurement for calculation of resistance. Do
not change the potential divider movable arm position.
9 This now results in : I _______ A
VD ______ V.

V
Therefore, R  D
= ............... ohms
D I
The result may vary considerably due to
4 Increase the supply voltage to the iron coil by adjusting different temperatures of the wire.
the potentiometer so that the current (I) reaches a value Conclusion
of 450mA.
What is the relationship between resistance and
5 Measure the voltage drop VD across the coiled wire. temperature?
6 From both the values (I and VD) calculate the resistance ______________________________________________
of the coil.
______________________________________________
______________________________________________

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.3.25 71

Power Exercise 1.4.26
Wireman - Basic Wiring Practice

Practice on installation and overhauling common electrical accessories as per

simple Electrical circuit / Layout
Objectives: At the end of this exercise you shall be able to
• identify specified electrical accessories used in domestic wring such as socket outlet, ceiling rose, fuse unit
fan regulators.
• dismantle the above accessories and identify the internal parts and over haul the even
• reasonable the accessories and check for its function.

Requirements
Tools and Instruments/equipment • Brass pendent-holder 6A 250V - 1 No.
• Bakelite pendent-holder 6A 250V - 1 No.
• Screwdriver 150mm with 4mm blade
• 3-pin 6A wall socket, mounting type - 1 No.
width - 1 No.
• 3-pin 16A, 250V wall socket,
• Connector screwdriver 100mm - 1 No.
mounting type - 1 No.
• Trader 10x10x4 cm - 1 No.
• 3-pin 6A, 250V wall socket, flush type - 1 No.
Materials • 3-pin 16A, 250V wall socket, flush type - 1 No.
• S.P. switch 6A 250V flush type, • 2-pin 6A, 250V wall socket, flush type - 1 No.
single way - 1 No. • 2-pin 6A, 250V mounting type - 1 No.
• S.P. switch 6A 250V flush type, • Ceiling rose 6A 250V 2 plate - 1 No.
two way - 1 No. • Ceiling rose 6A 250V 3 plate - 1 No.
• S.P. switch 6A 250V mounting type, • Fan regulator - 1 No.
single way - 1 No. • Kit-kat fuse 16A 250V - 1 No.
• S.P. switch 6A 250V mounting type, • 3-pin 6A 250 V plug - 1 No.
two way - 1 No. • 3-pin 16A 250 V plug
• Brass batten-holder 6A 250V - 1 No.
• Bakelite batten-holder 6A 250V - 1 No.

PROCEDURE
TASK 1: Identify each accessory and write their haules

1 Identify each accessory and write the name in the space 3 Dismantle the accessory carefully.
provided.
Open only one accessory at a time. Take care
Different manufacturers design the outline of of the fixing screws, rings and washers.
accessories differently to suit various
Collect the parts in the tray. Metal parts inside
conditions. However, the electrical contact
the accessory need not to removed.
postions of hte accessories remain the same.
As such there should not be much difficulty in 4 Compare the actual internal parts of the given accessory
identifying the accessories. with the internal view of each accessory given in the
sheets for identification. Identify the servicable parts.
On the other hand, single way and two-way
switches as well as two and three plate ceiling 5 Fill up the answers in the identification column given
roses look alike. A careful look at the rear of against each (accessory) figure.
the accessory will make the identifying process 6 Identify the symbols used for the accessory from the
much easier. related theory or B.I.S. books and sketch the symbols
2 Write the specification of each accessory in the column in the colomns/spaces provided.
given by the side of each (accessory) figure. 7 Show the completed sheets of specifications
Most of the specifications can be collected from identification and symbols to the instructor and get his
the markings on the accessory itself. Otherwise approval.
try to get them from an approved catalogue or
approach the instructor for guidance.

72
a Name & specification ______________________________________________
Write the name and specfication of the given accessory. ______________________________________________
(Fig 1)
______________________________________________
______________________________________________
3 How would you identify 2-way switches from single way
______________________________________________ switches without opening the covers.
______________________________________________ ______________________________________________
______________________________________________
______________________________________________
4 Name the material of which the body of the switch is
made.
______________________________________________
Draw the recommended symbols

in layout diagram in circuit diagram

Over haul the accessory, reassemble and check for it
correct function.
C Name & specification
Write the name and specification of the given accesswory.
(Fig 2)
Identification ______________________________________________
Name the parts against the numbers of Fig 1. ______________________________________________
1 _____________________ 2 _____________________ ______________________________________________
3 _____________________ 4 _____________________ ______________________________________________
Name the parts against the numbers in Fig 1.
2 _________________________________________
3 _________________________________________

Draw the recommended symbols

in layout diagram in circuit diagram

Over haul the accessory, reassemble and check for it
correct function.
b Name & specification
Identification
Write the specification of the two way switch supplied.
Name the parts against the numbers of Fig 2.
______________________________________________
1 _____________________ 2 _____________________
______________________________________________
3 _____________________ 4 _____________________
______________________________________________
State the size of the profile to be cut for mounting the
______________________________________________ switch on a board of Fig 2.
Identification ______________________________________________
1 Draw the material view of the given switch. ______________________________________________
2 Identify the parts ______________________________________________
______________________________________________

Power: Wireman (NSQF Level - 4) - Exercise 1.4.26 73

 Draw the recommended symbols

in layout diagram in circuit diagram

Over haul the accessory, reassemble and check for it
correct function.
d Name & specification
Write the name and specification of the given accessory.
(Fig 3)
______________________________________________
______________________________________________
Identification
______________________________________________
Identify the three plate ceiling rose from the stock.
The look of this accessory is similar to that of another
accessory. Name that accessory.
______________________________________________
______________________________________________
Draw the recommended symbols

in layout diagram in circuit diagram

Over haul the accessory, reassemble and check for it
correct function.
Identification f Name & specification
Name the parts against the numbers in Fig 3. Write the specification of the given accessory. (Fig 5)
1 _____________________ 2 _____________________ ______________________________________________
3 _____________________ 4 _____________________ ______________________________________________
Name the material of which the following parts are made ______________________________________________
in Fig 3.
______________________________________________
1 _________________________________________
2 _________________________________________
Draw the recommended symbols

in layout diagram in circuit diagram

Over haul the accessory, reassemble and check for it
correct function.
e Name & specification
Write the name and specification of the given accessory.
(Fig 4)
______________________________________________
______________________________________________ Identification
______________________________________________ Identify the parts against the number in Fig 5.
______________________________________________ 1 _____________________ 2 _____________________
3 _____________________ 4 _____________________
5 _____________________ 6 _____________________
74 Power: Wireman (NSQF Level - 4) - Exercise 1.4.26
 Draw the recommended symbols

in layout diagram in circuit diagram

Over haul the accessory, reassemble and check for it
correct function.
g Name & specification
Write the name and specification of the given accessory.
(Fig 6)
______________________________________________ Identification

______________________________________________ Identify the parts against the number in Fig 7.

______________________________________________ 1 _____________________ 2 _____________________

______________________________________________ 3 _____________________ 4 _____________________

7 _____________________ 8 _____________________
of what material are the following parts made?
Parts No. 3 of Fig 7
Parts No3 8 of Fig 7
Draw the recommended symbols

in layout diagram in circuit diagram

Over haul the accessory, reassemble and check for it
correct function.
i Name & specification
Write the name and specification of the given accessory.
Identification
(Fig 8)
Identify the parts against the number in Fig 6.
______________________________________________
1 _____________________ 2 _____________________
______________________________________________
3 _____________________ 4 _____________________
______________________________________________
6 _____________________ 7 _____________________
______________________________________________
What is the purpose of part No. 7 of Fig 6.
______________________________________________
Draw the recommended symbols

in layout diagram in circuit diagram

Over haul the accessory, reassemble and check for it
correct function.
h Name & specification
Write the name and specification of the given accessory.
(Fig 7)
______________________________________________
______________________________________________
______________________________________________

Power: Wireman (NSQF Level - 4) - Exercise 1.4.26 75

Identification Over haul the accessory, reassemble and check for it
correct function.
Identify the parts against the number in Fig 7.
k Name & specification
1 _____________________ 2 _____________________
Write the name and specification of the given accessory.
3 _____________________ 4 _____________________
(Fig 10)
5 _____________________
______________________________________________
Draw the recommended symbols
______________________________________________
______________________________________________
______________________________________________
in layout diagram in circuit diagram
Identification
Over haul the accessory, reassemble and check for it
correct function. Identify the parts against the number in Fig 10.
j Name & specification 1 _____________________ 2 _____________________
Write the name and specification of the given accessory. 3 _____________________ 4 _____________________
(Fig 9)
7 _____________________ 8 _____________________
______________________________________________
______________________________________________
______________________________________________
______________________________________________

Identify the material by which the following parts are made.

2 ________________________________________
3 ________________________________________
Identification Draw the recommended symbols
Identify the parts against the number in Fig 9.
1 _____________________ 2 _____________________
3 _____________________ 4 _____________________ in layout diagram in circuit diagram

7 _____________________ Over haul the accessory, reassemble and check for it

correct function.
Name the material of which the following parts are made.
l Name & specification
1 ________________________________________
Write the name and specification of the given accessory.
4 ________________________________________ (Fig 11)
5 ________________________________________ ______________________________________________
Draw the recommended symbols ______________________________________________
______________________________________________
______________________________________________
in layout diagram in circuit diagram

76 Power: Wireman (NSQF Level - 4) - Exercise 1.4.26

 Draw the recommended symbols

in layout diagram in circuit diagram

Over haul the accessory, reassemble and check for it
correct function.

Identification
Identify the parts against the number in Fig 11.
1 _____________________ 2 _____________________
3 _____________________ 4 _____________________
7 _____________________ 8 _____________________

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.4.26 77

Power Exercise 1.4.27
Wireman - Basic Wiring Practice

Fixing of switches, holder plugs etc. in T.W. boards

Objectives: At the end of this exercise you shall be able to
• select the correct size of board to mount specified accessories
• position the accessories and mount them on the T.W. board
• wire up and test the test board.

Requirements
Tools and Instruments/equipment Materials
• Combination pliers 200 mm - 1 No. • T.W. hinged box 375x250x80 mm - 1 No.
• Screwdriver 200 mm with 5 mm blade - 1 No. • B.C. batten lamp-holder 6A 250V - 2 Nos.
• Screwdriver 150 mm with 3 mm blade - 1 No. • Flush mounting 250V 6A 3-pin socket - 3 Nos.
• Poker 200 mm - 1 No. • Flush mounting 250V 6A S.P.T. swtich - 2 Nos.
• Firmer chisel 12 mm - 1 No. • PVC copper cable 3/20 - 2 m.
• Try square 150 mm - 1 No. • 14 SWG G.I. wire - 1 m.
• Tenon-saw 300 mm - 1 No. • 12 mm No.5 wood screws - as reqd.
• Gimlet 5 mm dia. 200 mm - 1 No. • 20 mm No.6 wood screws - as reqd.
• Ball peen hammer 250 gms - 1 No. • 25 mm No.6 wood screws - as reqd.
• 4 mm drill bit - 1 No. • Neon lamp flushh-mounting 250V
• Connector screwdriver 100 mm - 1 No. with holder 6A - 1 No.
• Hand drilling machine 6 mm capacity - 1 No. • BC bulb 60W, 250V - 1 No.
• Mallet 75mm dia. head with handle - 1 No. • Kit-kat fuse-carrier with base
• 4 fold wooden rule 60 cm - 1 No. flush-type 16A 250V - 1 No.
• Keyhole saw 200 mm - 1 No. • Insulated terminals non-detachable
4mm plug entry - 3 Nos.
• Flush-mounting type D.P. switch
250V 20 A with neon indicator - 1 No.
• Twin-twisted flexible wire 23/0.2mm - 5 metres.

PROCEDURE
1 Identify the D.P. switch, its incoming/outgoing terminals 5 Place the accessories on the cardboard to suit the
and its operation. Identify a neon lamp and its technical and aesthetic aspects and draw a layout.
connection. Select the size of the T.W. board accordingly.
2 Form the circuit as per the schematic diagram Fig 1, 6 Compare the layout the drawn by you with the layout
using a flexible wire for the testing circuit. given in Fig 2 and discuss with your co-trainees about
their merits and de-merits.
7 Mark the position of the double-pole switch and other
accessories on the T.W. board as per the given layout
(Fig 2) and the supplied drawing of the front panel.
(Fig 3)

3 Get the formed circuit checked by the Instructor.

If incorrect, make necessary changes.
4 Give rated supply and test the circuit.

78
 12 Route the connecting cables between accessories
neatly, harness (strap-bunch) the cables.
13 Connect the acccessories and the insulated terminals
after identifying phase and neutral.
14 Connect the earth wire with earthing terminals of socket
outlets, one of insulated terminals and the double pole
switch. A completed test board will look as shown in
Fig 4.
15 Provide bulbs in the lamp-holders.
16 Get the approval from your instructor and test the test
board.

8 Cut profiles for fixing the accessories to the T.W. board

and drill holes for cable entries, insulated terminals
and fixing screws, and make pilot holes wherever
necessary.
9 Fix the electrical accessories on the T.W. board.
10 Fix three numbers of insulated terminals.
11 Measure and cut cables for harnessing, according to
the circuit diagram. (Fig 1)
Use the B.I.S. recommended colour code for
cable connections within the test board
__________

Power: Wireman (NSQF Level - 4) - Exercise 1.4.27 79

Power Exercise 1.4.28
Wireman - Basic Wiring Practice

Identification and use of wiring accessories concept of switching

Objectives: At the end of this exercise you shall be able to
• identify the wiring accessories with name and specifications
• identify the wiring accessories symbol and its uses
• practice on use of one way, two way, pull, push and intermediate switch in electrical circuit.
• practice on concept of switching.

Requirements
Tools and Instruments/equipment • Intermediate switch - 1 No.
• Lamp 250V 60W - 1 No
• Wire stripper 150 mm - 1 No.
• Connecting wire 1mm2 - as reqd.
• Connector screwdriver 75 mm - 1 No.
• KDP 16A - 1 No.
• Combination plunger 200 mm - 1 No.
• Kit-kat fuse - 1 No.
Materials • HRC fuse - 1 No.
• Ceiling rose - 1 No.
• One way switch 250V 6A - 1 No.
• 16A Socket - 1 No.
• Two way switch 250V 6A - 2 Nos.
• 16A Plug - 1 No.
• Toggle switch 5A - 1 No.
• Holders all types - 1 set.
• Pull switch 250V 6A - 1 No.
• 4 way PVC junction box - 1 No.
• Push switch 250V 6A - 1 No.
• Connecting wires - as reqd.

PROCEDURE
TASK 1: Identify the correct electrical accessories and write their uses name, specification and uses
1 Identify the electrical accessories and write their name
againt the figure.
2 Write their specification and uses in Table 1.
Table 1
Name Specification Use
1 Controlling accessories

80
 Name Specification Use

2 Holding accessories

Power: Wireman (NSQF Level - 4) - Exercise 1.4.28 81

 Name Specification Use

3 Safety accessories

4 Outlet accessories

82 Power: Wireman (NSQF Level - 4) - Exercise 1.4.28

 Name Specification Use

5 General accessories

__________

TASK 2: Practice on conccept of switching

1 Connect the switches as per Fig 1.

When anyone of the switch position change

the lamp will glow. Lamp/Load controlled from
two places is the purpose of two way switches.
2 Switch 'ON' switches and aboserve the lamp will glow
and will not glow in 'OFF' position. 7 Connect the switches as per Fig 3.
As 'S1' is an one way switch only ON0/OFF If the Lamp/Load controlled from more than
purpose. two places an Intermediate switch should be
used
3 Switch 'ON' switch, S2 (Pull switch) by pulling the rope,
the lamp (4) glows and the lamp will go OFF when the 8 Change the position of S1-S2 and Intermediate switch
same rope pull again. and control the lamp from three places.
As 'S2' is a pull switch the output is ON/OFF
according to the every pulling of rope.
4 Switch 'ON' S3 (Push switch) the lamp is glowing untill
the switch is in pushing position.
5 Connect the switches as per Fig 2.
6 Both switch S1 and S2 are same position the maope
not glow.
__________
Power: Wireman (NSQF Level - 4) - Exercise 1.4.28 83
Power Exercise 1.5.29
Wireman - Cells and Batteries

Assembly of Dry cell- Electrodes-Electrolytes

Objectives: At the end of this exercise you shall be able to
• construct a dry cell
• measure the voltage of the cell with multimeter.

Requirements
Tools and Instruments/equipment Materials
• Digital multimeter (or) • Carbon rod 8mm x 75mm - 1 No.
Analog D.C. voltmeter (0-50V) - 1 No. • Ammonium chloride gel - 100 gm.
• Zinc container (150 ml) - 1 No.

PROCEDURE
1 Select and collect the identified materials used to
assemble the dry cell.
2 Get the approval from the trainer by showing collected
materials.
3 Fill the ammonium chloride gel in the zin container as
shown in Fig 1.

7 Take the readings of the meter which shows the actual

4 Place the carbon rod at the centre of container and
voltage of the assembled dry cell.
seal the container without leakage.
Multimeter shows 1.5V
Avoid the contact of carbon rod and zinc
container.
5 Select the range of 0-1000V D.C in digital multimeter/
D.C analog voltmeter.
6 Touch the positive probe (Red colour) at carbon rod
and negative probe (Black colour) at zinc container as
shown in Fig 2.
__________

84
Power Exercise 1.5.30
Wireman - Cells and Batteries

Practice on Grouping of Dry cells for a specified voltage and current, Ni cadmium
and Lithium cell
Objectives: At the end of this exercise you shall be able to
• make grouping of cells in series connection
• make grouping of cells in parallel connection
• make grouping of cells in series and parallel connection.

Requirements
Tools and Instruments/equipment Materials
• MC Ammeter 0-1A - 1 No. • Cells 1.5V (Nickel cadmium) - 8 Nos.
• MC Voltmeter 0-15V - 1 No. • SP Switch 6A, 250V - 4 Nos
• MC Ammeter 500 mA - 1 No. • Connecting leads - as reqd.
• Multimeter - 1 No. • Resistor 5 , 10W - 1 No.
• Rheostat 20 ohms 3.7A - 1 No. • 4 Cell battery pack - 2 Nos.
• miniature lamp 6V / 9V, 300 mA - 1 No.
• Resistor 10  , 10W - 1 No.

PROCEDURE
TASK 1: Grouping of cells in series connection
1 Check the individual cells for their condition.
• Select 500 mA DC current range in mulimeter or
500 mA DC ammeter.
• Connect the cell across the meter in series with a
3 ohm resistor.
• Watch the deflection.
Full deflection shows good condition of cell.
Low deflection shows disharged condition of
the cell.

Cells having a higher internal resistance should

not be used for series connection.
Care should be taken for the cells polarity. 5 Connect the terminal ‘G’ to the terminal A and observe
2 Connect the cells as in Fig 1. the ammeter reading and the glow condition of the lamp.
3 Measure the voltage of one cell V1, two cells V2, three 6 Change the contact of termnal ‘ G’ terminals B,C and
cells V3 and four cells V4 connected in series. D in succession.
4 Record your observations in the first and second 7 Record your observations under the columns 3 & 4 in
columns of Table 1. Table 1.

Table 1
Sl No. No. of cells in series Voltmeter reading Ammeter reading Glow

4
__________

85
TASK 2: Grouping of cells in parallel connection
1 Check the voltage of each cell. Table 2
2 Form the circuit as shown in Fig 2. Sl.No. No. of Cells in Parallel V I

Unequal voltage cells cannot be connected in

parallel.
Conclusion
When cells of equal voltage are connected in parallel
the terminal voltage is equal to _________________
As the load current is shared by the cells in parallel,
the terminal voltage across the load is __________
when compared to a single cell supplying current to
the same load.
The effect of a number of cells in parallel to a given
3 Close the switch S1 and measure voltage and current.
load.
Record the values in Table 2, under columns 2, 3
and 4. ___________________________________________
4 Check and record the readings of V and I after closing ___________________________________________
switch S2, then S3, and S4 in succession.
___________________________________________
__________

TASK 3: Grouping of cells in series and parallel combination connection

Series parallel combination is for higher

voltage and higher current
1 Set the movable arm of 20 ohms 3.7A rheostat to get
12 ohms with the help of an ohmmeter.
2 Connect four 1.5 V cells in series to form one group.
Form one more similar group of 4 cells. (Fig 3)
3 Connect two series groups of 4 cells and form the circuit
as shown in Fig 3.
4 Close switch S1, observe the voltmeter and ammeter.
Record the values in row 1 of Table 3
5 Keep the switch positions S1, S2 and S3 as indicated
in row 2 of Table 3. Record V and I in the respective
columns.
6 Repeat step 5 for different combinations of switch
positions as indicated in rows 3 to 6 of Table 3.
Both the open circuit voltages of group (a) and Conclusion
group (b) should be the same, or more correctly
When group `A' alone supplies the load current, the fall in
their Terminal Potential Difference should be
voltage (EMF - TPD) is __________________________
the same when supplying the same load
current.

86 Power: Wireman (NSQF Level - 4) - Exercise 1.5.30

When group ‘B’ alone supplies the load current the fall in Note - Lithium and Nickel cadmium cells can
voltage (EMF - TPD) is __________________________ also be grouped as series and parallel
This indicates that the internal resistance of group ‘A’ is connections where the results of voltage and
__________________________the internal reistance of current will be same as the grouping of
group ‘B’ dryccells.
The no-load voltage in series-parallel combination The only advantage of Nickel cadmium and
______________________________________________ Lithium cells is that it can be recharged and
reuse.
The total current drawn by the load is equal to the sum of
the ___________________________________________

Table 3

Position of the switches

Row I1 I2 V
S1 S2 S3

1 Close Open Open

2 Close Open Close

3 Open Close Open

4 Open Close Close

5 Close Close Open

6 Close Close Close

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.5.30 87

Power Exercise 1.5.31
Wireman - Cells and Batteries

Practice on Battery Charging, preparation of battery charging

Objectives: At the end of this exercise you shall be able to
• connect and charge the battery by using a battery charger
• connect and charge the battery by the constant current method
• connect and charge the battery by the constant potential method.

Requirements
Tools and Instruments Materials
• Cutting plier 150 mm - 1 No. • Distilled water - 1 bottle
• Screw driver 150 mm - 1 No. (450ml)
• MC Voltmeter 0-15V - 1 No. • Petroleum jelly - as reqd.
• MC Ammeter 0-10A - 1 No. • Sandpaper (Smooth 120) - as reqd.
• Hydrometer - 1 No. • Test leads with crocodile clips - 1 pair
• High rate discharge tester - 1 No. • Clips - 1 pair
• Concentrated sulphuric acid - 100 ml
Equipment/Machines • Clean jar for mixing 1 litre capacity - 2 Nos.
• Battery charger for 12V - 1 No. • Cotton Waste - as reqd.
• Low voltage DC power supply • Soda bi-carbonate - as reqd.
0-30 volts 10A. - 1 No.
• Variable resistor 10 ohms, 5A capacity - 1 No.
• Battery 12V lead acid type - 1 No.

PROCEDURE
TASK 1: Prepare the battery for charging
1 Clean the battery terminals, if corroded, with sandpaper
: if sulphated, clean with wet cotton waste or with soda
bicarbonate.
Do not damage the battery terminal by
scraping with any metal strip.
2 Unscrew all the vent plugs and check the level of the
electrolyte.
Do not clean the battery top surface keeping
the vent plugs open. The accumulated dirt may
fall inside the cells and form sediments.
3 Top up the electrolyte to the marked level in all the 5 Measure the cell voltage and the battery voltage with a
cells with distilled water. voltmeter and record in the Table 1.
No electrolyte to be used to top up battery. Do not use a high rate discharge tester for
measuring voltage.
4 Check the initial specific gravity of the electrolyte of
each cell using a hydrometer (Fig 1) and record in
Table 1.

88
 Table 1

Initial condition Charged condition after

Cell No. 1 Hr 2 Hrs 3 Hrs 4 Hrs 5 Hrs
Specific Voltage
gravity
SP V SP V SP V SP V SP V

1
2
3
4
5
6

__________

TASK 2: Practice on battery charging using battery charger

1 Connect the battery charger's +ve lead to the +ve 4 Check the voltage of each cell of the battery and specific
terminal of the battery and the -ve lead of the charger gravity of the electrolyte at regular intervals (say ONE
to the -ve terminal of the battery. (Fig 2) hour).
Remove the vent plug to enable the gas to
escape.
5 Disconnect the battery when fully charged. Fit the vent
plugs, clean the outer surface with wet cloth. Apply
petroleum jelly to the terminals.
6 Check the battery for its working voltage under load
using a high rate discharge tester for a short period.
(Fig 3)

2 Adjust the battery charger output voltage equal to or a

little higher than the voltage of the battery to be charged.
3 Set the charger voltage to produce the determined value
of initial charging current.
Follow the manufacturer's recommendation for
current setting for charging as well as Do not keep a high rate discharge tester for a
discharging. long period, say more than five seconds.

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.5.31 89

Power Exercise 1.5.32
Wireman - Cells and Batteries

Testing of cells, Installation of batteries, Charging of batteries by different

methods
Objectives: At the end of this exercise you shall be able to
• check the new battery for any external defects (crack/leaks)
• check the battery room and install wooden racks for installation of battery
• install battery charger
• install the new battery
• test the installed battery for its good condition
• prepare electrolyte.

Requirements
Tools and Instruments • Porcelain/ synthetic insulator - as reqd.
• Lead acid type battery (each 2V/2Ah) - 6 pairs
• Electrician tool kit - 1 Set.
(total 12V)
• Voltmeter 0-15V MC - 1 No.
Materials
• Ammeter 0-10A MC - 1 No.
• Voltmeter 0-300V MI - 1 No. • Fresh electrolyte for initial filling - as reqd.
• Ammeter 0-10A MI - 1 No. • Petroleum jelly - as reqd.
• Hydrometer - 1 No. • Sandpaper - as reqd.
• High rate discharge tester - 1 No. • Clean tray for filling electrolyte - 1 No.
• Connecting leads (insulated)
Equipment/Machines
battery clamps - as reqd.
• Battery charger for 12V/4AH - 1 No.
• Low voltage DC power supply
0-30 volts 10A. - 1 No.
• Wooden rack - as reqd.

PROCEDURE
TASK 1: Test the battery before installation for its condition

Assume the new battery which is fully charged • Check for correct polarities on the battery terminals.
and kept ready for installation. a by paint ................... Red & Green
1 Read interpret and record the name plate details of the b by impression ................... (+) & (-)
battery in Table 1.
c Individual cell voltage and specific gravity.
Table 1
• Test and measured the voltage.
Type of battery - Lead acid battery
(+) to earth .................. volts
Make - .........................
(-) to earth .................. volts
Rating per cell - ................ V/Ah
(+) to (-) .................. volts
No. of ccells - ........................
Each cell of the battery charged by commercial
Electrolyte (H2SO4) - ..................Ltrs. battery charger. The initial voltage per cell for
2 Check and record the following parameters of the battery fully charged condition should be 2.1 volts /
to be installed. cell and specific gravity is not less than 1280.
• Check for the following battery room painted with The level of the electrolyte 10-15mm above the
acid proof paint. plate (Follow the manufacturers instruction if
any)
• Battery room provided with exhaust fan.
Never install any battery if not fully charged.
• Battery stand coated with acid proof stand. (Yes/
No)
• Battery stand rest on porcelain/synthetic insulator.

90
TASK 2: Install battery on the stand and connect through battery charger and test it
1 Check and confirm each cell for any damages and for
its fully charged conditions. (Refer Task 1)
2 Arrange wooden racks in rows to install the cells.
3 Install battery charger after inspection.
4 Calculate for series and parallel bank of cells (12V/4
Ah).
5 Arrange cells 6 Nos in series of two set and connect
string A and string B in series as in Fig 1.

6 Connect string A and string B in parallel as in Fig 2.

8 Connect the positive terminal and negative terminal of
the battery bank to the DC source for connecting to
system loads.
9 Get the connection checked by the Instructor.
10 Connect AC source to the charger and check the AC
input voltage.
11 Adjust DC output to the required voltage (say 12V).
12 Adjust charging current to the calculated value of trickle
charging current.
13 Test the voltage and specific gravity of each cell and
record the same in maintenance register as reference
value.
14 Check DC output voltage and current.
Record DC output voltage ...............
Record DC output current ...............
7 Connect the charger to the series/parallel. Connection
of the group cell as in Fig 3.
__________
TASK 3: Charge a battery by constant current method
1 Form the circuit as shown in Fig 4. 2 Clean the battery terminals and unscrew all the vent
plugs.
3 Check the level of the electrolyte and top up.
4 Check the specific gravity and voltage of each cell and
record and prepare a blank table (as shown in Table 1).
5 Connect the given batteries in series with the lamp
bank as per Fig 4.
6 Adjust the current rating through the lamp bank.
7 Set the lamp bank to produce the determined value of
the initial charging current.

Power: Wireman (NSQF Level - 4) - Exercise 1.5.32 91

 Don't touch the battery terminals since the 8 Read the voltage and specific gravity of each cell at
circuit is connected to 220V DC. regular intervals and record in Table 1.

Proper protective devices should be provided 9 Repeat the steps 10 and 11 of Task 1.
in the circuit.

__________

TASK 4 : Charge a battery by constant potential method

1 Form the circuit as shown in Fig 5.
2 Repeat the steps 2 to 4 of Task 2.
3 Adjust the voltage by adjusting the rheostat to the
required value.
4 Read and record the voltage, current and specific gravity
at regular intervals in Table 3. (Prepare a blank table
as shown in Table 1)
5 Repeat the steps 10 and 11 of Task 1.

__________

TASK 5: Preparation of electrolyte

1 Prepare the necessary materials for electrolyte 4 Allow the mixture to cool sufficiently to the ambient
preparation. temperature.
2 Fill distilled water of the required quantity in the glass 5 Read the specific gravity (Fig 1). If the specific gravity
jar. is below 1250, add a little more acid to bring to the
correct specific gravity.
3 Add concentrated sulphuric acid little by little to the
water and stir with a glass rod simultaneously. Take care not to sprinkle the electrolyte.
Don't pour excess acid at a time to the water
to avoid excess generation of heat.

__________

92 Power: Wireman (NSQF Level - 4) - Exercise 1.5.32

Power Exercise 1.5.33
Wireman - Cells and Batteries

Practice on Electroplating and anodizing, Cathodic protection

Objectives: At the end of this exercise you shall be able to
• carryout the procedure of electroplating
• analyse cathodic protection
• perform anodizing process.

Requirements
Tools and Instruments/equipment • Electro plating bath with all
arrangement - 1 No.
• Trainees tool kit - 1 No.
• Zinc rod - 1 No. Materials
• H2SO4 Sulphuric acid - 10 ltrs. • Chromium rod - 1 No.
• Cathode article spoon - 1 No.
Equipments/Machines
• 16V/100A DC Supply - 1 No.

PROCEDURE
TASK 1: Carryout electroplating process and analyse cathodic protection
1 Collect the required materials and equipment for
electroplating as in Fig 1.
3 Fill the sulphuric acid (H2SO4) in the plating tank.
4 Connect chromium rod as anode so as to dip
completely in acid.
5 Switch ON and regulate the current and voltage as
required level.
Generally 0-16V DC supply used for electro
plating process.
After completion of electro plating process
colour of cathode is changed to white.
Cathodic protection in known as control of
corrosion.
2 Dip the article which is to be electro plated in 6 Connect zinc rod as additional anode to protect the
hydrochloric acid. article to be plated.
__________
TASK 2: Perform the anodizing process

Anodizing is known as the reverse process of

electro plating.
1 Suspend the aluminium article at anode electrode and
antimonial at lead cathode Fig 2.
2 Start the process for a while.
3 Continue the proccess after confirming the converting
operation.
4 Complete the process.
5 Spray distilled water at the aluminium article.
This process is known as anodizing which is
used to form a layer of aluminium oxide that
will protect aluminium beneath it. 6 Get it checked with your instructor.
__________
93
Power Exercise 1.5.34
Wireman - Cells and Batteries

Routine, care and maintenance of Batteries

Objectives: At the end of this exercise you shall be able to
• prepare and follow the routine care/maintenance schedule chart for batteries
• carry out the general procedure and maintenance for batteries.

Requirements
Tools and Instruments/equipment Equipment/Machines
• Ring spanner (6 mm - 25 mm) - 1 Set • Lead acid battery 12V / 60 AH - 1 No.
• Combination pliers 150mm - 1 No.
Materials
• Insulated screw driver 200mm - 1 No.
• Hydrometer - 1 No. • Banian cloth - as reqd.
• High rate discharger tester - 1 No. • Distilled water - as reqd.
• Sodium bicarbonate solution - as reqd.

PROCEDURE
TASK 1: Prepare and follow the routine care/maintenance schedule chart for batteries

1 Collect the care/maintenance activities required for lead 3 Perform the routine care/maintenance activities of
acid batteries. battery by referring the following chart 1.
2 Make a care/maintenance chart for daily, weekly,
monthly, six monthly maintenance schedule as in
chart - 1.
Routine Care/ Maintenance Schedule Chart-1
Sl.No. Routine Activities to be done Remarks
1 Daily • Inspect the batteries visually.
• If it is found abnormal, report and do necessary action.
2 Weekly • Inspect all batteries visually
• Clean surface, check tightness of connectors and vent plugs
• Check supporting clamps
3 Monthly • Check level of electrolyte
• Do charging of battery, if not been automatically charged
• Clean terminals, reconnect, apply protection jelly.
• Clean top surface by sodium bi carbonate solution in water.
• Wipe surface for dryness.
• Check that other materials surface should not have contact
with batteries and top surface of battery
4 Six Monthly • Check level and specific gravity, charging rate, charging hours,
voltage cell

(Life of well maintained lead acid battery can be about five

to six years)

__________

94
TASK 2: Carry out the general preventive maintenance of lead acid battery
1 Perform the following steps for the preventive
maintenance of battery.
Steps to be followed for preventive maintenance of
battery

• Maintain the level of the electrolyte 10 to 15 mm • Apply a thin layer of Vaseline (or) petroleum jelly
above the plates (or) as per manufacturer's over them to prevent corrosion.
manual.
• Do not charge or discharge the battery in higher
• Add the distilled water to the acid; and do not rate continuously.
add acid to water.
• Remove the lead sulphate which is formed due to
• Connect the positive terminal of the battery to over charge after four months.
the positive terminal of the supply, and connect
• Maintain well-ventilated room for battery charging.
the negative terminal of the battery to the negative
terminal of the supply while charging the battery. • Use high rate discharge tester only for charged
battery not for discharged battery.
• Keep the vent plug open for the liberation of gases
during charging. • Check the specific gravity of the electrolyte before
charging and discharging.
• Clean the vent plugs holes for proper discharging
of gas.
• Keep the battery terminals always cleaned.

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.5.34 95

Power Exercise 1.5.35
Wireman - Cells and Batteries

Charging of a Lead acid cell, filling of electrolytes- Testing of charging

checking of discharged and fully charged battery
Objectives: At the end of this exercise you shall be able to
• connect and charge the battery by using a battery charger
• test the battery for its charging condition using hydrometer and high rate discharge tester.

Requirements
Tools and Instruments • Variable resistor 10 ohms, 5A capacity - 1 No.
• Battery 12V lead acid type - 1 No.
• Cutting plier 150 mm - 1 No.
• Screw driver 150 mm - 1 No. Materials
• MC Voltmeter 0-15V - 1 No. • Distilled water - 1 bottle
• MC Ammeter 0-10A - 1 No. (450ml)
• Hydrometer - 1 No. • Petroleum jelly - as reqd.
• High rate discharge tester - 1 No. • Sandpaper (Smooth 120) - as reqd.
Equipment/Machines • Test leads with crocodile clips - 1 pair
• Hydrogen peroxide - as reqd.
• Battery charger for 12V - 1 No. • Clips - 1 pair
• Low voltage DC power supply • Concentrated sulphuric acid - 100 mp.
0-30 volts 10A. - 1 No. • Clean jar for mixing 1 litre capacity - 2 mm

PROCEDURE
TASK 1: Charging a battery using a battery charger and test it

1 Clean the battery terminals, if corroded, with sandpaper

: if sulphated, clean with wet cotton waste or with soda
bicarbonate.
Do not damage the battery terminal by
scraping with any metal strip.
2 Unscrew all the vent plugs and check the level of the
electrolyte.
Do not clean the battery top surface keeping
the vent plugs open. The accumulated dirt may
fall inside the cells and form sediments.
3 Top up the electrolyte to the marked level in all the 6 Connect the battery charger's +ve lead to the +ve
cells with distilled water. terminal of the battery and the -ve lead of the charger
No electrolyte to be used to top up battery. to the -ve terminal of the battery. (Fig 2)

4 Check the initial specific gravity of the electrolyte of 7 Adjust the battery charger output voltage equal to or a
each cell using a hydrometer (Fig 1) and record in little higher than the voltage of the battery to be charged.
Table 1. 8 Set the charger voltage to produce the determined value
5 Measure the cell voltage and the battery voltage with a of initial charging current.
voltmeter and record in the Table 1. Follow the manufacturer's recommendation for
Do not use a high rate discharge tester for current setting for charging as well as
measuring voltage. discharging.
9 Check the voltage of each cell of the battery and specific
gravity of the electrolyte at regular intervals (say ONE
hour).

96
 11 Check the battery for its working voltage under load
using a high rate discharge tester for a short period.
(Fig 3)

Remove the vent plug to enable the gas to

escape. Do not keep a high rate discharge tester for a
10 Disconnect the battery when fully charged. Fit the vent long period, say more than five seconds.
plugs, clean the outer surface with wet cloth. Apply
petroleum jelly to the terminals.

Table 1

Initial condition Charged condition after

Cell No. 1 Hr 2 Hrs 3 Hrs 4 Hrs 5 Hrs
Specific Voltage
gravity
SP V SP V SP V SP V SP V

1
2
3
4
5
6

__________

Power: Wireman (NSQF Level - 4) - Exercise 1.5.35 97

Power Exercise 1.6.36
Wireman - Basic Workshop Practice

Marking use of chisels and hacksaw on flats, sheet metal filing practice, filing
true to line
Objectives: At the end of this exercise you shall be able to
• mark parallel lines using surface gauge
• punch by dot/centre punch
• chip flat surface using cold flat chisel
• saw on flat along a straight line
• file and finish surfaces an sheet metal.

Requirements
Tools and Instruments • Flat cold chisel 14mm&100mm - 1 No.
• Ball peen hammer 200gm - 1 No.
• Try square (engineers)- 150mm - 1 No.
• Centre punch 100 mm - 1 No. Equipments/machines
• Dot punch - 1 No.
• Bench vice - 1 No.
• Hack saw frame with blade 300mm - 1 No.
• File flat bastard double list 300 mm - 1 No. Materials
• File flat second cut, double cut 300 mm - 1 No. • 60 ISF 8 (length 150 mm) - 1 No.
• Steel rule 300 mm - 1 No.

PROCEDURE
TASK 1: Practice on marking
1 Check the raw material size using the steel rule. 4 Place the job on the parallel plate and scribe the lines
as per measurement.
2 Check the squareness of the job using try square
(Fig 1). 5 Punch mark the line (Fig 2).
3 Apply chalk on the surface evenly.

__________
TASK 2: Practice on chipping
1 Place the marked job in the vice and properly grip it. 3 Install a chip guard to prevent chips flying off (Fig 4).
2 Support a wooden block to the work piece if necessary
(Fig 3).

Remove bangles and wrist watches.

98
4 Position the chisel to cut the metal in uniform thickness
(Fig 5).

The cutting edge of the chisel is looked at, and

not the head of the chisel.
5 Stop the chipping before end of the surface to prevent
the edge of the job from breaking off (Fig 6).
6 Chip from the end of the job from the opposite direction.
(Fig 7)
Hold the hammer at the end of the handle for
maximum leverage. Instructor demonstrate the
uses of other types of chisels.
__________
TASK 3: Pracice on hacksawing
1 Securely fix the job in the bench vice.
2 Fix the blade to the Frame in good Tenion (Fig 8).

Do not use force when pulling back.

The teeth of the blade should point from the
handle. 5 Make the last few cuts, holding the piece to be cut in
your left hand. (Fig 11)
3 Set your thumb nail vertically to the location of the cut,
and the location should be atleast 10mm from then
vision. (Fig 9)

Occationally apply cutting compound while

cutting.
4 Hold and press the hacksaw straight (Fig 10). Use full length of the hacksaw balde.
__________
TASK 4: Practice on filing true to line
1 Check the length and size of the flat. 3 Place the work piece on the levelling plate and mark it
2 Test the flatness and right angle with the try square. as per requirement. (Fig 12)

Power: Wireman (NSQF Level - 4) Exercise 1.6.36 99

 4 Punch all the lines.
5 File the sides D & E with a bastard file.
6 Finish it with a second cut file.
7 Use out side caliper for checking finished sizes.
8 Deburr all sharp edges.

__________

TASK 5: Pracice on sheet metal filling

1 Check the dimensions of the given metal sheet. 5 If the work piece is small hold the work piece in one
hand and deburr by smooth file. (Fig 16)
2 Mark the lines using steel rule and scriber. (Fig 13)

3 Cut the sheet as per markings by using snips. (Fig 14)

6 If the work piece is larger in size, place if on the work
bunch and deburr. (Fig 17)

4 Deburr the sides and edges of the sheet by using flat

smooth file. (Fig 15)
Apply low pressure on files.

__________

100 Power: Wireman (NSQF Level - 4) Exercise 1.6.36

Power Exercise 1.6.37
Wireman - Basic Workshop Practice

Sawing and planning practice. Practice in using firmer chisel and preparing
simple half lap joint
Objectives: At the end of this exercise you shall be able to
• mark lines on wooden planks, using try square, straight edge and steel rule, and test flatness and squareness
• cut the given planks, with a handsaw and tennonsaw to the required sizes
• set the jack plane blade for rough and fine cut
• plane the surfaces and edges of the batten and board using a jack plane, true to the try square and to the
required width and thickness
• make the pin socket on the wood
• make the half lap joint.

Requirements
Tools and Instruments/equipment • Firmer chisel 75 mm, 35mm - 1 No.
• Ball pein hammer 0.51 - 1 No. each
• Handsaw 450mm - 1 No. • Mallet - 1 No.
• Straight edge 600 mm - 1 No. • Jack plane - 1 No.
• Try square 200 mm - 1 No. • Work benck with vice (10cm jaw) - 1 No.
• G. Clamp No.6 - 1 No. Materials
• Mark of gauge - 1 No.
• Hardwood 340x200x30 mm - 1 piece.

PROCEDURE
TASK 1a: Practice on sawing on wood by using hand saw
1 Check the raw material size.
2 Draw 4 lines parallel to the edge along the grain with 4 Fix the piece on the workbench with a 'G' clamp. Check
10 mm spacing between the lines using pencil and the cut along the grain-marked portion is clear of the
straight edge on one face of the given wooden piece. workbench top.
Extend these lines to both ends using a try square Do not overtighten the 'G' clamp.
and connect them on the other face, using a straight
edge. (Fig 1) 5 Start cutting along the grain on the first line from the
edge with a hand saw.
Use a well sharpened saw for good results.
Saw with even strokes using the full length of
the saw blade.
Keep your eye on the line being cut.
Keep your left hand away from the cutting edge
of the saw while sawing.
6 Repeat sawing on the remaining 3 lines, one after the
other.
3 Draw 4 lines across the grains on one face from one
end with 20 mm spacing between the lines using a 7 Remove the 'G' clamp and fix the wooden piece such
pencil and try square and extend these lines on both that the marked portion across the grain is clear of the
edges and the other face using a try square. (Fig 2) workbench top.
8 Start cutting across the grain on the first line from the
end with a tenon-saw.
9 Repeat sawing on the remaining 3 lines, one after the
other. Check whether the board size is 260 x 160 mm
(Fig 3).
10 Repeat sawing the wood every day to produce atleast
6mm thick and 300mm long from 25 mm thickness
plank.
101
 __________
TASK 1b: Practice on sawing on wood by using tenon saw
1 Identify the grain direction of the piece prepared under 6 Check the piece with a straight edge/steel rule and try
Task 1. square for squareness and size of 155 x 245 x 30 mm.
(Fig 4)
2 Draw a line parallel to the edge along the grain using a
steel rule/straight edge and a pencil keeping the width
of the board 155 mm.
3 Draw a line across the grains from one end measuring
245 mm length of the board.
4 Saw along the grains to the marked line with a hand
saw.
5 Saw across the grain to the marked line with a tenon-
saw.
Saw with even strokes using the full length of
the saw blades.
__________

TASK 2: Planning practice

Maintain proper pressure on the plane while

planing.
4 Check the flatness with a try square across the length
and check the straightness with a straight edge along
the length.
5 Indicate this finished face as a reference surface with
a pencil mark.
6 Hold hte batten in the bench vice, and plane the edge
straight and square to the face. Lay the plane on its
side to protect the cutting edge of the blade when not
in use.
7 Check for squareness and straightness of the finished
edge and make a pencil mark to indicate it as the
reference edge.
8 Set the marking gauge to 30 mm and mark a line for
the width of the batten on both the faces.
9 Plane the batten edge holding on the bench vice and
remove the excess material up to the marked line.
1 Check the raw material size. 10 Set the marking gauge for 25mm, and mark for the
thickness of the batten on both edges.
2 Set the jack plane for planing. Use a well sharpended
plane blade. 11 Fix the batten in the vice and plane the other face to
remove the excess material up to the marked lines.
3 Place the batten on the workbench against the bench
stop; plane on face of the batten flat and straight. 12 Check the planed batten for its dimensions - 255x30x25
mm.
102 Power: Wireman (NSQF Level - 4) Exercise 1.6.37
13 Plane on face of the board, used in the previous 22 Set the smoothing plane for a moderate cut.
exercise, flat.
23 Plane the end of the board by using the smoothing
14 Check for its flatness (using a try square) and also plane half way from both the edges.
check it lengthwise and diagonally with a straight edge.
24 Test the squareness of the end from the face end edge
15 Plane the edge of the board flat and square to the face. using a try square.
16 Set the marking for 150mm and mark the line for the 25 Mark the length of the board as per the drawing, using
width of the board on both the faces. steel rule, try square and scriber on both faces and
both edges.
17 Plane the other edge to the marked line.
26 Cut the extra portion using a tenon-saw, keeping the
18 Set the marking gauge for 25 mm and mark for
saw thickness on the waste side.
thickness on both the edges.
27 Plane the other end (steps 21 to 24).
19 Plane the other face to the marked line and check this
face for flatness. While setting the plane blade, face the source
of light.
20 Check the planed board to the dimensions of
240x150x25 mm. For protection of the cutting edge of the blade,
withdraw the plane blade into the plane before
21 Hold the board firmly in a vertical position in a
keeping the jack plane in the tool kit.
carpenter's vice, keeping the end of the board projecting
25 mm to 30 mm above the vice jaws.
__________

TASK 3: Practice in using firmer chisel and preparing single half lap joint

Check the size of the given place. 3 Mark both the pin and socket pieces as per the drawing.
4 Check the markings as per drawing.
5 Hold the piece in the vice.
6 Cut the shoulder line down to the centre of the face
edge using tenon saw. (Fig 2)

7 Cut on the waste side on the line.

8 Hold the piece in vertical position in the vice. (Fig 3)

1 Plane the piece as per required size 50x20x300mm.

2 Saw it into two pieces of sizes 50x20x180 (socket)
and 50x20x120mm (pin).
Power: Wireman (NSQF Level - 4) Exercise 1.6.37 103
9 Cut the centre line down to the shoulder. (This cut 15 Chisel off the waste positions. (Fig 8 and 9)
should be on the waste side of the line).
10 Complete the cut.
11 Smooth the surface with paring chisel as shown in
Fig 4 and 5 and complete it.

Socket piece
12 Hold the socket piece in the vice.
13 Saw close to the marked line (shoulder line) up to the
depth of 10mm using tenon saw. (Fig 6)

16 Smooth the trench surface side and side walls with

firmer or parting chisel. (Fig 10)

17 Assemble the pin and socket pieces together. (Fig 11)

14 Make several saw cuts as in Fig 7.

18 Check the squareness of the job/joint.

__________

104 Power: Wireman (NSQF Level - 4) Exercise 1.6.37

Power Exercise 1.6.38
Wireman - Basic Workshop Practice

Drilling practice in hand drilling and power drilling machines. Grinding of drill
bits
Objectives: At the end of this exercise you shall be able to
• drill pilot holes matching the sizes of screws with a hand drill machine or an electric hand drilling machine
• drill holes of larger diameter after pilot drilling.
• sharpen drill bits.

Requirements
Tools and Instruments/equipment • Pillar electric drill machine
12 mm capacity - 1 No.
• Steel rule 300 mm - 1 No.
• Grip drill machine - 1 No.
• Try square 200 mm - 1 No.
• Marking gauge - 1 No. Materials
• `G' Clamp No.6 - 1 No.
• 58 ISP length 300 mm
• Hand drill machine 6 mm - 1 No.
(Finished part of previous exercise)
• Ratchet brace - 1 No.
• Drill bit S.S.6 mm - 1 No.
• Bench vice 50 mm jaw - 1 No.
• Countersunk bit 6 to 10 mm - 1 No.
Equiment/Machines • Drill bit SS 3 mm - 1 No.
• Portable electric hand drilling
machine (6 mm) - 1 No.

PROCEDURE
TASK 1: Practice on drilling pilot holes using hand drilling machine
1 Mark lines with a marking gauge, 15 mm from each 3 Punch the hole centres with the centre punch /
end, according to the drawing for the central line of sharpened nail.
pilot holes. (Fig 1)
4 Fix the job on the workbench with the bench vice `G'
2 Mark hole centres as per the drawing with a steel rule clamp.
and pencil from one edge on the central lines already
5 Drill 3 mm diameter. pilot holes to a depth of 15 mm at
drawn, on both the faces.
the locations already marked by using hand drilling
Mark hole locations within ± 0.5 mm accuracy. machine.
Do not drill holes deeper than specified.

__________
105
TASK 2: Practice on drilling holes with larger diameter after pilot drilling
1 Punch the centre of the hole to be drilled using a centre 4 Fix the drill chuck into the spindle of the drilling machine
punch (90°). after cleaning the mating parts.
2 Punch witness marks using a 60° prick punch on the 5 Select a smaller diameter drill as a pilot drill before
periphery of the hole to be drilled. (Fig 2) using the required large size drill.
The diameter of the pilot drill/ hole should be
at least equal to the web thickness of the large
drill.
Since, the web of large diameter drills are
thicker, the dead centres of those drills do not
seat in the centre punch marks. This can result
in the shifting of the hole location. Thick dead
centres cannot easily penetrate into the
material and will place severe strain on the
drill.
These problems can be overcome when we
drill pilot holes initially. (Fig 5)

These witness marks guide to ensure that the

hole drilled is exactly in its place.
If the drilled hole is perfectly located, half
witness marks are visible at the circumference
of the hole. (Fig 3)

6 Securely fix the drill deep into the drill chuck. (Fig 6)

3 Set the job securely in the machine vice on the parallels.

Make sure that the largest size drill to be used
must clear the parallel during drilling. (Fig 4)

7 Determine the speed of the spindle (r.p.m.) from the

recommended cutting speed and the diameter of the
drill or use a table and get the r.p.m.
8 Open (or) remove the belt guard and change the belt to
the pulley of the required cutting speed or to the nearest
r.p.m. and replace the gaurd.
Do not change the belt when the spindle is
rotating. (Fig 7)

106 Power: Wireman (NSQF Level - 4) Exercise 1.6.38

 14 Gradually reduce the feed force as the drill reaches
the bottom of the hole.
9 Run the spindle and check that the drill is rotating and 15 Withdraw the drill from the hole and switch OFF the
in the clockwise direction (from right to left). machine.
10 Bring the drill point and centre punch mark in line by 16 Remove the pilot drill and the drill chuck from the
adjusting the vice. When the alignment is satisfactory, machine. (Fig 6)
clamp the vice to the machine table. (Fig 8a & b).
17 Fix a large diameter drill into the machine spindle
11 Recheck the alignment. Switch ON the machine and directly.
feed the drill gently on to the work. Recheck the starting
of the drill. 18 Determine and reset the spindle speed (r.p.m.).
12 Use a steady force and feed the drill gently into the Note that the bigger the diameter of the drill is
job. lesser than the r.p.m. and greater than the feed.
13 Provide continuous flow of cutting fluid to prevent 19 Drill to enlarge the hole with steady feed. Stop the
overheating of the drill. machine, remove the job and clean the chips using a
brush.
__________

TASK 3: Practice on sharpening of drill bits

1 Check the grinding wheel for loading, glazing, trueness The hand near the point of the drill should be
and cracks. Call your instructor for advice. Dress and pivoted lightly on the tool rest at 'x' for easy
true the wheel if necessary. manipulation. (Fig 2)
2 Protect your eyes either with goggles or by lowering
the eye protecting shield near the tool rest and adjust
the tool nrest at 2 mm closer to the wheel, if necessary.
3 Check if enough coolant is there in the container.
4 Switch the grinder on.
5 Hold the shank of the drill lightly in one hand between
the thumb and the forefinger, and with the other hand
hold the portion near the point. (Fig 1)
6 Hold the drill level (Fig 2) and turn it to 59° to the face
of the wheel and swing the drill slightly downward and
towards the left. (Fig 3 & 4)

Power: Wireman (NSQF Level - 4) Exercise 1.6.38 107

7 Rotate the drill to the right by turning it between the 9 Check both the cutting edges with a drill angle gauge,
thumb and the forefinger. (Fig 4) for correctness of the lip angle and same in size of the
lip lengths. (Figs 5 & 6)
10 Check the lip clearance angle in Fig 5 visually. The
angle should be between 8° to 12°.

This turning movement is not necessary for

drills of smaller diameters.
While swinging and turning the drill make sure
you do not grind the other cutting edges.
All movements of the drill for angular turning,
swinging and forward movements should be
well coordinated. They should result in one
smooth movement to produce a uniformly
finished surface.
8 Repeat the process to re-sharpen the other cutting
edges.

__________

108 Power: Wireman (NSQF Level - 4) Exercise 1.6.38

Power Exercise 1.6.39
Wireman - Basic Workshop Practice

Practice in using taps & dies, threading hexagonal and square nuts etc
Objectives: At the end of this exercise you shall be able to
• form internal thread by hand tap and wrench
• cut external threads using dies
• cut threads in regional and square nuts.
• determine tap drill sizes for hexagonal and square nut
• cut internal threads on hexagon and square nuts using tap and tap wrench
• match nuts with bolts.

Requirements
Tools and Instruments • Angle plate - 1 No.
• Surface plate - 1 No.
• Surface gauge - 1 No.
• Drilling accessories chuck
• Hacksaw frame 250 to 300mm - 1 No.
sleeve and driff - 1 No.
• Ball pane hammer 200 gm - 1 No.
• M10 tap and wrench - 1 Set. Materials
• Steel rule 300 mm - 1 No.
• Hexagonal nut (available size) - 1 No.
• Twist drill 8.5 and 11.5 - 1 No each.
• Square nut (available size) - 1 No.
• Die set - 1 No.
• Lubricant oil - as reqd.
Equipment/Machines
• Bench vice (100 mm) - 1 No.
• Drilling machine pillar type - 1 No.

PROCEDURE
TASK 1: Practice in using taps
Drilling a hole Do not clear the chips by blowing as it can
1 Determine the tapping drill size using the table for cause injury to your eyes.
tapping drill size. 4 Screw a matching a hexogonal nut on the first tap to
2 Drill a blind hole using the depth stop arrangement. act as a depth stop. (Fig 2)
The depth of the tapping hole should be slightly more 5 Thread the blind hole until the nut touches the plate
than the depth of the required thread. (Fig 1) surface.

7 Finish tapping the hole with intermediate and bottoming

Procedure for threading tap (Fig 4). Set the nut to control the depth of the thread.

3 Remove metal chips, if any, from the blind hole by 6 Remove the chips from the hole frequently, using a
turning it upside down and slightly tapping it on wooden flattened and bent wire. (Fig 3)
surface.

109
8 Repeat and practice the step from 4 to 7 for forming
internal thread on square nut also.

__________
TASK 2: Practice in using dies
1 Fix the die in the diestock and place the leading side
of the die opposite to the step of the diestock.
(Fig 1 & 2)

Use vice clamp for ensuring a good grip in the

vice.
Project the blank above the vice - just the
required thread length only.
2 Place the leading side of the die on the chamfer of the
work. (Fig 3)

110 Power: Wireman (NSQF Level - 4) Exercise 1.6.39

3 Make sure that the die is fully open by tightening the
centre screw of the diestock. (Fig 4)

6 Cut slowly and reverse the die for a short distance in

order to break the chips.
Use a cutting lubricant.
7 Increase the depth of the cut gradually by adjusting
the outer screws.
8 Check the thread with a matching nut.
9 Repeat the cutting unitil the nut matches.
Too much depth of cut at one time will spoil
the threads. It can also spoil the die.
4 Start the die, square to the bolt centre line. (Fig 5) Clean the die frequently to prevent the chips
5 Apply pressure on the diestock evenly and turn in a from clogging and spoiling the thread.
clockwise direction to advance the die on the bolt blank.
(Fig 5)
__________

TASK 3: Practice in threading hexogonal and square nuts

Hexagonal nut 5 Check the threaded hole with screw pitch gauge and
matching bolt.
1 Check the raw material for its size.
6 Clean the thread in bolt and nut.
2 Hold the nut in bench vice parallel to vice jaws.
7 Match the nut with bolt as shown in Fig 2.
3 Fix M10 first tap in tap wrench and cut internal thread
as per drawing. 8 Apply a little oil and preserve it for evaluation.
4 Similarly, fix M10 second tap, third tap and cut and
form the full thread.
5 Check the threaded hole with screw pitch gauge and
matching bolt.
6 Clean the thread in bolt and nut.
7 Match the nut with bolt as shown in Fig 1.
8 Apply a little oil and preserve it for evaluation.
Square nut
1 Check the raw material size 15 mm.
2 Hold the but in bench vice parallel to vice jaws.
3 Fix M 12 first tap in tap wrench and cut internal thread
as per drawing.
4 Similarly, fix M 12 second tap, third tap and cut and
form full internal thread.

Power: Wireman (NSQF Level - 4) Exercise 1.6.39 111

 __________

112 Power: Wireman (NSQF Level - 4) Exercise 1.6.39

Power Exercise 1.6.40
Wireman - Basic Workshop Practice

Cutting external threads on stud and on pipes, riveting practice

Objectives: At the end of this exercise you shall be able to
• prepare the conduit pipe ends for threading and fastening in a pipe vice
• cut the threads on heavy gauge metal conduit according to requirement using a conduit die set
• cut the external thread on bolt (stud)
• drill holes in the sheet metal with drilling machine rivit with rivet set.

Requirements
Tools and Instruments Equipment/Machines
• Hammer 250g - 1 No. • Hand drilling machine 6mm - 1 No.
• Pipe vice 50mm - 1 No.
Materials
• Steel rule 600mm - 1 No.
• Hacksaw with blade of 24 teeth • Bolt/stud (available size) - 1 No.
per 25 mm - 1 No. • Conduit pipe 19 mm dia. 3m long - 1 No.
• Falt file bastard 200mm - 1 No. • Lubricant - coconut oil - 100 grams.
• Half round file bastard 200mm - 1 No. (for a batch of 16 trainees)
• Oil can 200 ml - 1 No. • Chalk piece - 1 No.
• Conduit stock and dies for 18 mm • Cotton waste - as reqd.
conduit - 1 Set. • Matchbox - 1 No.
• Wire brush 50mm - 1 No. (For a batch of 16 trainees)
• Centre punch - 1 No. • Sheet steel ISST 55x0.5x105 - 2 Nos.
• Scriber - 1 No. • No 14 Tinman's river - 10 Nos.
• Rivet set - 1 No.

PROCEDURE
TASK 1: Preparation of conduit pipe for threading
1 Open the jaw of the vice and insert the pipe so that it is Make the depth of the chamfer equal to the
horizontal and parallel to the jaw serrations. pitch of the thread (1.5 mm for conduit).
2 Keep the end of the tube within 150 mm of the vice. 5 Choose the correct dies and stock suitable for the pipe
3 Close the tighten the vice as shown in Fig 1. to be threaded.
Assembly drawing for the quick cut stock and
dies is given the Fig 3. The die size is engraved
on the die itself. Check the size with that of the
pipe.

4 File the end of the tube flat and chamfer the outer edge
to an angle of about 20º as shown in Fig 2.

113
6 Insert each half of th die in the cap (stock) with the The lubricant allows the die to cool off the heat
chamferred threads (leading faces) being adjacent to developed and thereby helps the edges to stay
the guide. sharp and to produce a better thread finish.
7 Screw the guide into position.
13 Make one or two complete turns in a clockwise
8 Adjust each adjusting screw equally to make thr die direction.
halves centralized to the pipe axis.
Check whether the stock is at right angle to
9 Slide the stock guide over the end of pipe, adjust the the pipe axis.
adjusting screws such that the ides just grip the pipe
As indicated by the increased resistance of
evenly on both sides.
rotation, ease the handle as frequently as
10 Apply pressure to the stock and keep the handles at necessary, back in an anticlockwise direction
right angles to the pipe as shown in Fig 4. for half a turn.
Reverse turning is necessary to break off long
cuttings and to clear the cutting edges of the
die.
14 Apply the lubricant at frequent intervals.
Use a brush to remove the metal burrs from
the die.
15 Remove the stock. Check the length and fit of the thread
by screwing on the female fittings (coupling etc.).
The length of the thread should be sufficient
to fit half way into the couplings and fully into
the other fittings.
16 If the thread is not smooth (i.e. tight in the fittings)
mount the stock and tighten the adjusting screws by
11 Rotate the handles clockwise in a plane at right engles half turn evenly and repeat working steps 10 to 15.
to the pipe axis as shown in Fig 5. 17 Remove any burrs or sharp edges from inside the end
of the pipe with a reamer or half round as shown in Fig
6, and file off the sharp edges, if any.
18 Clean the die stock and vice. Keep them in their
respective places.

12 Apply the lubricant to the part to be threaded after the

thread has been started.
__________
TASK 2: Cut external threads using dies
1 Select a correct size and circular rod as blank and
chamfer the ends.
Blank size - Thread size - 0.1% pitch of the thread
2 Grip the blank in the vice using a false jaw, projecting
the blank above the vice jaws 5 mm more than the
required length of thread.
3 Fix the die in the diestock.
The leading side of the die must be opposite
to the step of the die stock. (Fig 1 & 2)

114 Power: Wireman (NSQF Level - 4) Exercise 1.6.40

4 Open the die fully by tightening the centre screw of the
die stock. (Fig 3)

5 Place the leading side of the die on the chamfer of the

job.
6 Start the die, square to the bolt centre line. (Fig 5&6)
7 Turn in the clockwise direction to advance the die on
the blank with even pressure on both ends of the die
stock.
8 Cut thread slowly and reverse the die for a short distance
in order to break the chips.
Use a cutting lubricant.
9 Clean the die frequently with a brush to prevent the
chips from clogging and also from spoiling the thread.
10 Reverse and remove the die after the full height is
reached.
11 Increase the depth of the cut gradually by loosening
the centre screw and tightening the side screws.
Too much depth of cut one time will spoil the
threads. It can also spoil the die.
12 Check the fit of threads with a matching nut.
13 Tighten the side screws by hand and repeat the cutting,
unitl the standard nut matches with the external, and
without undue 'play' between the threads.

__________

TASK 3: Practice on riviting sheet metal joints

1 Check the dimension of the given sheet iron. 7 Draw the material and the rivet together tightly by placing
the hole in the rivet set and striking the set one or two
2 Mark straight line for centre line of the rivet. (Fig 1)
sharp blows with hammer.
3 Mark centres for drilling with centre punch.
8 Place the cup shaped hole on the rivet and give the
4 Drill holes using the hand drilling machine. rivet set one or two sharp blows with the hammer to
5 Place together the two pieces of sheet metal on a head the rivet.
suitable solid plate. 9 Rivet alternately in each direction, beginning with the
6 Insert the rivet in the hole, that is nearest to the centre nearest centre hole.
of span, resting the head of the rivet on the place. 10 Insert the rivet in the holes made in the sheets.
11 Draw the rivet and the sheet together by striking one or
two sharp blows with a hammer.

Power: Wireman (NSQF Level - 4) Exercise 1.6.40 115

 To set the rivet firmly in the sheet, use a rivet set. The
rivet head is to be supported with a dolly. A dolly is
used to prevent the rivet head from expanding when it
is struck with the hammer.

The shank is to be rounded by giving glancing blows

with the hammer (as shown in Fig 4) for firming the
head.

12 Perform heading the rivet with th cup shaped hole of

the rivet set and hammer.

13 In thin plates the holes for rivets are punched as shown

in Fig 1.
Finally, place the rivet snap on the rivet (as shown in
Fig 5) and finish the work by giving a few blows with
the hammer.

Pass the rivet through the punched hole in the sheet

as shown in Fig 2.

__________

116 Power: Wireman (NSQF Level - 4) Exercise 1.6.40

Power Exercise 1.6.41
Wireman - Basic Workshop Practice

Practice in using snips, marking and cutting of straight and curved pieces in
sheet metals
Objectives: At the end of this exercise you shall be able to
• mark straight lines of given dimensions
• mark curved lines of given dimensions using divider
• shear straight edge using straight snip
• shear along curved line using bent snip.

Requirements
Tools and Instruments/equipment • Mallet (wood) - 1 No.
• Hatchet stake available size - 1 No.
• Steel rule 300mm - 1 No.
• 'G' clamp 250mm - 1 No.
• Scriber 200mm - 1 No.
• Straight snips 250mm - 1 No. Materials
• Bent snip 250mm - 1 No.
• Sheet iron ISST 220 x 0.5 x 300
• Divider 200mm - 1 No.
(Same sheet used in Exercise 221A)
• Hammer ball peen 200g - 1 No.

PROCEDURE
1 Check the dimension of the given sheet iron. 4 Make indent mark with prick punch (tip angle - 30º).
(Fig 3)
2 Using the steel rule, mark the required dimension for
straight lines as per diagram. (Fig 1)

5 Transfer the radius measurement from steel rule to

divider. (Fig 4)
3 Locate centre d1 for curve 4 as per measurements in
the drawing. (Fig 2)

6 With the point d1 as centre, scribe the curve 4. (Fig 5)

117
 10 Shear along line 2 using straight snips.
11 Shear along line 3 in part A using straight snips.
12 Shear along curve 4 using bent snip. (Fig 7)
13 Shear along curve 5 using bent snip.

7 With the same centre and radius reduced by 1mm,

scribe the guide mark.
8 Repeat steps 3 to 7 for curve 5 with d2 as centre.
9 Shear along line 1 using straight snips. (Fig 6)

__________

118 Power: Wireman (NSQF Level - 4) Exercise 1.6.41

Power Exercise 1.6.42
Wireman - Basic Workshop Practice

Bending the edges of sheets metals

Objectives: At the end of this exercise you shall be able to
• mark straight lines of given dimensions
• mark curved lines of given dimensions using divider
• shear straight edge using straight snip
• shear along curved line using bent slip
• cut 90º notch using snip
• bend to 90º using vice, angle plate, mallet, G-clamp.

Requirements
Tools and Instruments/equipment • Mallet (wood) - 1 No.
• Hatchet stake available size - 1 No.
• Steel rule 300mm - 1 No.
• 'G' clamp 250mm - 1 No.
• Scriber 200mm - 1 No.
• Straight snips 250mm - 1 No. Materials
• Bent snip 250mm - 1 No.
• Sheet iron ISST 220 x 0.5 x 300
• Divider 200mm - 1 No.
(Same sheet used in Exercise 221A).
• Hammer ball peen 200g - 1 No.
• Angle plate - 1 No.
• Vice - 1 No.

PROCEDURE
1 Check the dimension of the given sheet iron.
2 Using the steek rule, mark the required dimension for
bending.
3 Place the sheet in angle steel. (Fig 1)

6 With a soft mallet hammer the projecting portions in

stages (15°, 30°, 45°, 60° and 90°) (Fig 4).

4 Gently hammer the marked portion by 90º.

Use wooden wallet for folding
5 Practice in bending by folding bar (Fig 2) and 'G' clamp
(Fig 3).

7 Cut both notches with the straight snioin part B.

(Fig 5).

__________
119
Power Exercise 1.6.43
Wireman - Basic Workshop Practice

Riveting practice in sheet metal. Practice in making different joints in sheet

metal in soldering the joints
Objectives: At the end of this exercise you shall be able to
• make a joint by soft soldering in sheet metal
• make a rectangular tray into flaps by soldering.

Requirements
Tools and Instruments • Soldering Bench - 1 No.
• Leveling plate - 1 No.
• Soldering iron with copper bit - 1 No.
• Straight snip 200mm - 1 No. Materials
• Straight edge 300mm - 1 No.
• 150 x 100 GI 5mm thick - 1 No.
• Mallet 200gm - 1 No.
• Soft solder 60x40 - as reqd.
• Metal brush 200mm - 1 No.
• Flux solder acid - as reqd.
Equipment/Machines • Cotton waste - as reqd.
• Tin Mans Anvil - 1 No.

Riveting practice refer Exercise No: 1.6.40

PROCEDURE
TASK 1: Make a joint by soft soldering in sheet metal
1 Clean the area to be joined thoroughly.
Where a lap joint is required on mild steel,
both sides of the top lap should be cleaned
and tinned, to assist heat transfer when
soldering.
2 Heat the copper of the soldering iron until the flame is
bright green. Keep the edge of the copper bit upward.
(Fig 1)

3 Dip the edge of the bit in flux solder-acid. (Fig 2)

The tip is tinned by rubbing it along the solder.
(Fig 3)
4 Place the sheet on a soldering bench. 5 Apply the flux on the area to be joined. (Fig 4)
6 Heat the soldering iron until the flame is green. Keep
the tip of the copper bit upwards. (Fig 1)
7 Dip the point into the flux.

120
 12 Apply more solder as required.
13 Turn the sheet over and tin the other lap area in the
same manner.
14 Clean off the excess flux using a wet rag/metal brush.
15 Get the soldered joint checked with your instructor.

This will remove the oxide film from the tinned

faces.
8 Apply more solder to the point. (Fig 5)
9 Apply the bit to the work.
10 Spread the solder evenly on the surfaces.
11 Keep the tinned face of the bit flat, to obtain maximum,
heat transfer.
__________
TASK 2: Make a rectangular tray into flaps soldering
1 Check the size of sheet as per sketch using a steel 6 Make a single hemming on the four sides of the tray.
rule. (Fig 6a) (Fig 6b)
2 Level the sheet on the levelling plate using a mallet. 7 Bend the four sides to 90º using a Tin man's anvil.
(Fig 6b)
3 Develop the tray by the parallel line method.
8 Join the four corners by soft soldering.
4 Cut the sheet as per lines by straight snips.
Fig 6b shows finished tray after soldering are
5 Cut the corners by straight snips. joined.

__________
Power: Wireman (NSQF Level - 4) Exercise 1.6.43 121
Power Exercise 1.7.44
Wireman - Magnetism and Capacitors - AC Circuits

Trace the magnetic field

Objectives: At the end of this exercise you shall be able to
• trace the magnetic field of the given magnetic bar
• trace the magnetic lines with the aid of a compass needle and iron fillings.

Requirements
Tools and Instruments/equipment • Aluminium wire - a few pieces
• Copper wire - a few pieces
• Bar magnet 12 x 6 x 100 mm - 2 Nos.
• Cotton thread sleeve - a few pieces
• Compass needle 10 mm diameter - 1 No.
• Wood chips - a small qty
Materials • Paper pins - as reqd.
• Iron fillings - 25 gms.
• Iron nails - 25 gms.

PROCEDURE
TASK 1: Trace the magnetic field of the given magnetic bar
1 Place the bar magnet's north pole underneath the paper 6 Place the bar magnet underneath a thin cardboard as
as in Fig 1. in Fig 3. Sprinkle some iron filings.
2 Sprinkle some iron filings on the paper. 7 Tap gently the paper to orient the iron filings and trace
the magnetic path with a pencil.

3 Tap the paper gently on all the corners. Observe the 8 Place another thin card over the bar magnet as in
random filings getting oriented into a definite pattern. Fig 4. Trace the magnetic lines using a compass needle
4 Draw the gently lines along the orientation of the iron by positioning the needle in the required areas..
filings with a pencil. For steps 6 and 7, the bar magnet should be
5 Repeat the expriment for the other pole as shown in oriented in the geometrical north-south
Fig 2. direction.
Do not use a strong bar magnet for mapping
the field with a compass.

__________
122
Power Exercise 1.7.45
Wireman - Magnetism and Capacitors - AC Circuits

Assembly / winding of a simple electro magnet

Objectives: At the end of this exercise you shall be able to
• prepare a bobbin
• select the suitable wire and make the winding for solenoid
• determine the pulling strength of a solenoid.

Requirements
Tools and Instruments • PVC insulated cable 4 sq.mm
250V grade - 4 m.
• Combination pilers 150 mm - 1 No.
• Barrator resistor 0.48 ohms 250W - 1 No.
• Screwdriver 100 mm - 1 No.
• Cardboard A4 (R 48) size - 1 No.
• Screwdriver 150 mm with 3 mm blade - 1 No.
• Bare copper wire 4 sq.mm - 1 m.
• Magnetic compass 12 mm diameter - 8 Nos.
• Porcelain connectors 2-way 32A - 2 Nos.
• Rheostat 10 Ohms, 20A - 1 No.
• Transparent sheet of plastic,
• MC Ammeter 0-10A - 1 No.
A4 size, 3 mm thick - 1 No.
• MC Ammeter 0-30A - 1 No.
• PVC saddles 50mm - 2 Nos.
• MC Voltmeter 0-15/0-25V - 1 No.
• PVC pipe 25 mm 100 mm long - 1 piece.
Equipment/Machines • PVC washer 25mm inner diameter.
• Battery 12V, 80 or 100AH or variable 50 mm outside dia. - 2 Nos.
voltage source DC 0-25V, 30A - 1 No. • PVC adhesive tape - as reqd.
• Super-enamelled copper wire
Materials 22 SWG - 50m.
• Iron filings - 50 gms • 4–way terminal pad - 1 No.
• Connecting leads - as reqd. • T W plank 150 mm x 300 mm - 1 No.
• DPST knife switch 16A/ 250V - 1 No. • Soft iron piece 22 mm dia 75 mm long
• Enamelled copper wire 16SWG - 50 cm with hook on one end - 1 No.
• Paper pins - a few • SPST Knife switch 16A - 1 No.
• Terminal post 16A - 2 Nos • Adhesive paste for fixing washers - as reqd.
• SPST knife switch 16A / 250V - 1 No. • PVC/Empire sleeve 2 mm - as reqd.

PROCEDURE
TASK 1: Make the solenoid and determine it's polarity for the given direction of current
1 Fix the PVC washers at both ends of the PVC pipe to 4 Find the number of turns wound over the bobbin for one
make the bobbin. (Fig 1) rotation of the drilling machine handle.
5 Calculate the number of handle rotations required for
winding 200, 400 and 600 turns.
6 Complete the windings by taking tapping at an interval
of every 200 turns (200, 400 and 600) such that the
common and three terminals are taken out through the
holes provided in the side wall (PVC washer). (Fig 2)

2 Fix the bobbin suitably in a hand drilling machine.

3 Secure the lead-out wire to the bobbin by means of an
adhesive tape after inserting the lead wire with sleeve
through the hole in the side wall of the bobbin.

123
7 Insulate the top layer with an adhesive insulation tape. Carefully remove the enamel insulation
(Fig 3) without damaging the conductor.
10 Check the continuity with an Ohmmeter.
11 Connect the ends of the solenoid to the 12V battery
through switch S, variable rheostat and ammeter 0 -
10A. (Fig 5)

8 Fix the solenoid on a 150 mm x 300 mm wooden board

using a plastic saddle. (Fig 4)
9 Connect the drawn out ends with sleeves to the 4-way
terminal pad, fixed on the board. (Fig 4)
12 Close the switch S and test the polarity of the solenoid
with a bar magnet which is, suspended with a thread.
13 Check the winded electro magnet in the presence of
Instructor and get approval.

__________

124 Power: Wireman (NSQF Level - 4) Exercise 1.7.45

Power Exercise 1.7.46
Wireman - Magnetism and Capacitors - AC Circuits

Use of magnetic compass

Objectives: At the end of this exercise you shall be able to
• identify the polarity of the magnetic compass
• determine the polarity of a permanent magnet by using compass.

Requirements
Tools and Instruments/equipment • Iron fillings - 25 gms
• Iron nails - 25 gms.
• Bar magnet 12 x 6 x 100 mm - 2 Nos.
• Cotton thread sleeve - a few pieces
• Magnetic compass with needle
• Wood chips - a small
10 mm diameter - 1 No.
quantity.
Materials • Paper pins - as reqd.
• Thread (tensionless) -1m

PROCEDURE
TASK 1: Trace the magnetic field of the given magnetic bar
1 Keep the magnetic compass on the table as shown in
Fig 1.
2 Observe the needle ends.
3 Turn the position of the compass and observe the
position of the needle.
4 Result: The needle end seeking the geometrical north
direction is the north seeking pole, or in general called
a ________________ pole. The other end is called a
_______________ pole.
__________
TASK 2: Draw the layout of wireman section workshop by using magnetic compass
1 Draw a line pm the floor parallel to the front wall of the
work shop by using a chalk as in Fig 2.

2 Keep the magnetic compass so that its 0º (zero degree)

and 180º are exactly on the line of chalk as in Fig 3.
3 Note the deflection of compass, and mark north
direction and south direction from the parallel line (for
example 30º displacement).
4 Draw the layout of your workshop and mark the direction
of the workshop as in Fig 4.
5 Show the layour to your instructor and get approval.

__________
125
Power Exercise 1.7.47
Wireman - Magnetism and Capacitors - AC Circuits

Identification of different types of Capacitors

Objectives: At the end of this exercise you shall be able to
• identify the type of capacitor by visual inspection
• identify the capacitor's value and rating from the marking.

Requirements
Tools and Instruments/equipment Materials
• Ohmmeter (multimeter - ohms range) - 1 No. • Capacitors - paper, mica, electrolytic,
mylar, tantalum,variable air core and
mica – assorted values and different
voltage ratings - as reqd.
• Potentrometer 100 k ohm - 1 No.

PROCEDURE
TASK 1: Identification of capacitors
1 Look at Figs 1(a) to 1(t). Identify the capacitors and
record your observations in Table 1.
2 Read the value of capacitance and working voltage from
the markings, if indicated, and record in Table 2.
3 Read the value of the capacitor and identify its type.
From the capacitor provided by the instructor.

126
 Table 1
Fig.No. Name of component Symbol Type Capacitance value Voltage rating

Table 2
Sl.No. Type Value of C in f Voltage V

4 Get it checked by your Instructor.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.7.47 127

Power Exercise 1.7.48
Wireman - Magnetism and Capacitors - AC Circuits

Charging and discharging of capacitor

Objectives: At the end of this exercise you shall be able to
• test the capacitor with DC supply for charge and discharge
• test the capacitor for charge and discharge by ohm meter.

Requirements
Tools and Instruments Materials
• MC Voltmeter (0-15V) - 1 No. • Capacitor 12V 470 f - 1 No.
• MC Ammeter (0-100mA) - 1 No. • Resistance 500  - 1 No.
Equipment/Machines • Sungle pole double throw switch 16A, 250V - 1 No.
• DC Sourcce 12V (or) 0-30V variable - 1 No.

PROCEDURE
TASK 1: Test the capacitor with DC supply for charge and discharge

1 Touch both leads of the capacitor with the voltmeter

(suitable range).
If there is any deflection, contact both leads
through a resistance for sufficiently a long time.

Do not touch the capacitor leads by hand. High

voltage retained by a charged capacitor will
give a severe shock.
2 Form the 12V circuit for testing the capacitor circuit
elements as in Fig 1. Keep the switches open.
3 Keep the switch S connected to the battery. Observe
the deflection in the ammeter and voltmeter. (Fig 1a)
4 Record the deflection in the ammeter whenthe switch
S is closed to position 1. (Fig 1b)
5 Observe the voltmeter reading at equal intervals of time.
(At least 4 readings from zero to the maximum
deflection.)
6 Record the time and voltage in Table 1.
7 Repeat steps 1 to 5 by changing the value of the series
resistor ‘R’ (increasing the value of R increases the
time).
8 Open the switch ‘S’ and observe the voltmeter reading
for 5 minutes.
9 Result
The voltage across the capacitor remains _________
because of _____________ condition of the capacitor.
10 Close the switch S to position 2 and observe the
voltmeter and ammeter readings. (Fig 1c)
11 Observe the deflection of the voltmeter:
a The voltage of the capacitor gradually decreases.

128
 b The current shoots to maximum at the instant switch Table 1
S is closed to position 2, then it decreases gradually,
Sl. Value of Time Voltage
indicating that the capacitor is losing charge.
No. Capacitor Resistor in volts
12 Repeat the test for different values of capacitance rated 
F 
k seconds
for different voltages.
The testing voltage should be close to the 1 470 500
voltage rating of the capacitor. 2
3
4
5 4370
6
7
8
9 470
10
11
12

__________

TASK 3: Testing of capacitor with ohmmeter

1 Discharge the given capacitor. Indication of test instrument Conditon of
2 Connect the ohmmeter to test the capacitor (Fig 2) Capacitor under test
and observe the deflection in the meter. Meter indicates some resistance Leakage
Set the ohmmeter selector switch at a higher No Deflection Open
range.
Defects and return back slowly Good condition
While testing with a polarised capacitor, the
positive terminal of the capacitor is to be Continuously shows zero
connected to the positive terminal of the reading Short
ohmmeter and the negative terminal to the
negative terminal of the ohmmeter. 4 Discharge the capacitor.
While testing with non-polarised capacitor 5 Perform the test in different capacitors.
(mica, ceramic, etc) the low values in fractions
of micro-farad will not show any deflection in Table 2
the ohmmeter. Sl. Value of Meter Result
3 Assess the condition of the capacitor under test, using No. Capacitor reading
the information available in Fig 2 and record the findings
in Table 2. 1

For electrolytic capacitor only.

__________
Power: Wireman (NSQF Level - 4) Exercise 1.7.48 129
Power Exercise 1.7.49
Wireman - Magnetism and Capacitors - AC Circuits

Testing of Capacitors using DC voltage and lamp

Objectives: At the end of this exercise you shall be able to
• charge the capacitor upto the marking voltage
• discharge the capacitor through the DC lamp.

Requirements
Tools and Instruments/equipment Materials
• Wireman Took kit - 1 Set. • 2 way 6A/250V - 1 No.
• Capacitor 0-300 MI - 1 No.
• Voltmeter 0-300 MI - 1 No.
• 5W 24V lamp with holer - 1 No.
• 1 Sq.mm Aluminium wire - 2 mtrs.

PROCEDURE
1 Collect and check the component for their condition. 3 Connect to supply and place two way switch position
in 1.
2 Form the circuit with components as in Fig 1.
4 Measure the reading of teh voltmeter and record it.
Voltmeter will show the source voltage the
capacitor charged to remain with nut.
5 Change the two way switch position to 2.
6 Note the lamp glows and slowly brightness reduced
and go to OFF position.
It indicates that the charged capacitor is
discharged through the lamp load.

__________

130
Power Exercise 1.7.50
Wireman - Magnetism and Capacitors - AC Circuits

Determine the characteristics of RL, RC and RLC in A.C. Circuits both in series
and parallel
Objectives: At the end of this exercise you shall be able to
• measure the current, voltage, power and P.F in R-L series and parallel circuits
• measure the current voltage, power and P.F in R-C, series and parallel circuits
• measure the current voltage, P.F in R-L-C series and parallel circuits
• measure the power and P.F. in R-L-C series and parallel circuits.

Requirements
Tools and Instruments Materials
• Digital multimeter - 1 No. • Connecting cables - as reqd.
• MI voltmeter 0 - 300 V - 3 Nos. • Choke (tube light) 40 W, 0.43 A,
• MI ammeter 0 - 1.5 A - 1 No. 250 V - 1 No.
• Wattmeter 250 V, 2.5 amps - 1 No. • I.C.D.P. switch - 16 amps, 250 volts - 1 No.
• Power factor meter (0.5 lag to • Wire wound resistor 500/0.5A - 1 No.
0.5 lead) 250 volts, 2.5 amps - 1 No. • Wire wound resistor 100/1.5A - 1 No.
• Frequency meter 50 H2 5 - 1 No. • Electrolytic capacitor 8Fd/400V - 1 No.
Equipment/Machines • Electrolytic 1Fd, 2Fd, 4Fd/400V - 1 each

• Auto transformer 0-270V/8A - 1 No.

• Reheostate 400/1A - 1 No.

PROCEDURE
TASK 1: Measure the current, voltage, power and P.F in R-L series circuit

1 Assemble the circuit by connecting instruments, resistor • Keep current as the reference vector.
R, inductor L as in Fig 1. Switch ON the supply.
• Select a suitable scale for the voltage.
2 Measure the voltage VR, VL, supply voltage VT and he
• Draw the voltage vector (VR) in-phase with current
circuit current and record in Table 1.
(I).
3 Read power (W1) and power factor (cos ) and record it
• Draw the voltage vector VL leading-current I by 90º.
in Table 1.
• Add vector VR and VL to get VT1
4 Calculate the apparent and the true power consumed
in the circuit and compare them. 7 Compare the above with the measured supply voltage.
5 Calculate the power factor and compare it with the 8 Calculate the power factor from the true power and
measured power factor.
W
6 Draw the vector diagram to add the voltage drops across Cos   ....................W
apparent power 2 V I
R and L. T
131
9 Compare the calculated power factor with the measured 11 Get it checked by the instructor.
power factor.
10 Repeat the steps changing two values for the resistor
and inductor and record them in Table 1 in columns 2
and 3.
Table 1
Measured value Calculated value

Sl. Circuit Supply Power Voltage Voltage Power Vector Difference Power Difference
No. current voltage consumed across across factor addition in VT1 consumed between
(Wattmeter resis- induc- (reading of VR and VT2 in circuit measured
reading) tance tance of P.F. and VL & calculated
meter) power factor
I VT1 W1 VR VL Cos 1 VT1 VT – VT1 W2= VTX Cos 1–
I X Cos 1 Cos 2

Resistance = Indictance =

Resistance = Indictance =

Resistance = Indictance =

Conclusion
The difference between vector addition of VR and VL with
respect to VT is due to ___________________________
______________________________________________
__________
TASK 2: Measure the current voltage, power and P.F in R-C series circuit
1 Test the capacitor with an ohmmeter for its condition. 6 Calculate cosö and impedance.
Discharge the capacitor before testing. 7 Compare the calculated P.F with measured P.F.
2 Check the value of the given resistance with a digital 8 Measure the voltages across R and C and note in
multimeter for its value. Table 3.
Check the suitability of the selected wattmeter 9 Compare the arithmetical sum of VR and VC with the
and P.F. meter with respect to the circuit supply voltage and observe that this is a wrong
specifications. procedure.
3 Construct the circuit as per diagram. (Fig 2) Keep the 10 Add VR and VC by the vector method (graphically)
switch ‘S’ open. selecting a suitable scale and compare with the
measured supply voltage.
Set the auto-transformer output to zero voltage.
11 Adjust the output voltage to 200 V and repeat steps 5
4 Close switch ‘S’ and adjust the auto-transformer output
to 10
voltage to 100V.
5 Measure the circuit current, voltage power consumed
and power factor and note the readings in Table 2.

132 Power: Wireman (NSQF Level - 4) Exercise 1.7.50

12 Get it checked by the instructor. Conclusion

Table 2 ______________________________________________

Measured Calculated ______________________________________________

V supply I W PF ______________________________________________
W V
PF  Z Table 3
VI I
V supply VR VC VR + VC VR + VC
(Arithmetic) (Vector)
100 V
100 V
200 V
200 V

__________
TASK 3: Measure the current voltage, P.F, in R-L-C series circuit

1 Assemble the circuit as per circuit diagram (Fig 3) with Table 4

the instruments and components collected.
Supply VR VL VC I
Before forming the circuit, confirm that the
capacitor is discharged. 240v
2 Switch ‘ON’ the supply and adjust the auto-transformer
until the voltmeter indicates 240 volts. 4 Measure the current and note the same in Table 4.
3 Measure the voltage across each element and note it Switch off the circuit.
in the Table 4.

Power: Wireman (NSQF Level - 4) Exercise 1.7.50 133

5 Draw the vector diagram (say 1cm = 50 V and 1cm 9 Replace the capacitor with another value, say 1.0
= 0.1A) taking the current as the reference vector. MFD and repeat the steps 2 to 7.
6 Determine the supply voltage from the vector diagram. 10 Result: Total measured voltage is _______________
Supply voltage (vector sum) =..................V ___________________________________________
Assumption: The resistance of the choke is 11 Get it checked by the instructor.
negligible in this case.
Conclusion
7 Compare the value of the resultant vector voltage with
A The voltage across individual component and total
reading of the voltmeter across the mains.
supply voltage _______________________________
If the vector sum of voltages VR VC VL is not
___________________________________________
exactly equal to the measured supply voltage,
it may be due to--- B The circuit current ____________________________
• observation error ___________________________________________
• drawing of the vector diagram incorrectly C The phase angle of current with supply voltage (from
voltage vector) _______________________________
• assumptions made.
8 Replace the capacitor with another value, say 8.0
MFD and repeat the steps 2 to 7.
__________

TASK 4: Measure the power and P.F. in R-L-C series circuit

1 Form the circuit as shown in Fig 4. 8 Increase the voltage to 200 volts and repeat steps
4 to 7.
Discharge the capacitor. With an ohmmeter
check the resistance for its value, the inductor Do not increase the voltage beyond 200V for
for its continuity and the capacitor for leakage. this circuit.
2 Set the auto-transformer to have zero output. Switch 9 Reduce the output voltage back to zero and switch off
‘ON’ the supply. the supply.
3 Gradually increase the output voltage until it is 100V. 10 Repeat the experiment (steps 2 to 9) with
4 Measure the corresponding current. Note down the i) the capacitor removed
readings in Table 5. Also read the Wattmeter and the
ii) a 2 micro-farad capacitor connected
power factor meter and record it in Table 5.
iii) a 8 micro-farad capacitor connected keeping the
5 Calculate the apparent power from voltmeter and
voltage at 200 V.
ammeter reading.
11 Compare the readings of the power factor in all the four
Apparent power = V x I in volt amp (VA)
cases. Record your observation.
6 Determine the power factor by using the formula and
12 Result
record it in Table 5.
The change of the capacitor in the R-L-C series circuit
True Power for given R-L (value)
Cos 
Apparent power ___________________________________________

7 Verify the measured power factor with the calculated ___________________________________________

power factor. ___________________________________________

134 Power: Wireman (NSQF Level - 4) Exercise 1.7.50

 Table 5

Sl. V Volt I Amp. W AP = V xI in VA W P.F. Meter Capacitor

Cos 
No. True power AP reading value in MFD

1 100V 4

2 200V 4

3 200V 0

4 200V 2

5 200V 3

13 Get it checked by the instructor.

__________

TASK 5: Measure the current, voltage in R-L parallel circuit

1 Assemble the circuit with the instruments, inductive 5 Draw the vector diagram with suitable scale for currents
coil and resistance. (Fig 5) taking voltage as reference vector in your practical
record.
6 Determine the total current graphically.
The calculated values of total current and the
actual measured value of current may vary due
to instrument error, observational error and
non-availability of pure inductance. Hence,
about 5% error is permissible.
7 Compare the total current measured with the calculated
value entered in Table 7.
Table 7
Sl.No. Measured Calculated
value value
V
Z
V IT
IT  I R  I L 
2 2 I
T

1 50

2 100
2 Set the auto-transformer output at zero position.
3 125
3 Switch ‘ON’ the supply and gradually increase the
output voltage to 50V. 4 150
4 Measure the branch and total currents and record in
Table 6. Repeat this step for different voltages say 100V, 5 175
125V, 150V, and 175V.
Table 6 8 Find the Impedance of the circuit from the supply voltage
and measured current. Calculate
Measured
Conclusion
Sl.No. V IR IL IT Graphical
IT Value Total current in an AC parallel circuit is the vector
________________ of IRand IL and not ______________
1 50
addition.
2 100
3 125
4 150
5 175
__________
Power: Wireman (NSQF Level - 4) Exercise 1.7.50 135
TASK 6: Measure the current and voltage in each branch circuits of R-C parallel circuits
1 Test the capacitor with an ohmmeter for its condition. 3 Build the circuit as per diagram. (Fig 6) Keep the switch
open. Set the auto-transformer to the minimum output
Discharge the capacitor before testing.
voltage.
2 Test the resistor with an ohmmeter for its value.

4 Switch ON the supply. Adjust the auto-transformer for 9 Establish that the arithmetical sum of the branch current
an output voltage of 200V. is not equal to the main circuit current.
5 Record the frequency, voltage and the three ammeter 10 Graphically add the currents I2 and I3 and determine
readings in Table 6. the value of I1. Compare this value with the measured
value.
6 Calculate the impedance ‘Z’ and record in Table 7.
11 Calculate the power factor from the recorded readings
7 Calculate the capacitive reactance (Xc = V/I3) and record
and enter the value in the space given below.
your result in Table 7.
8 Calculate the capacitance from the values recorded in
Table 7.
Table 7
Sl.No. V f I1 I2 I3 V V 1
Z X  C
I C I 2fX
1 3 c

12 Adjust the supply voltage to about 100 V and repeat ___________________________________________

steps 5 to 10.
___________________________________________
Discharge the capacitor after the experiment.
iii The vectorial sum of the branch currents and the
13 Repeat the exercise for changed values of R and C in measured value of the total current.
the circuit.
___________________________________________
Conclusions
___________________________________________
i The calculated value and the indicated value of the
___________________________________________
capacitor
iv The determination of PF from the vector diagram
___________________________________________
___________________________________________
___________________________________________
___________________________________________
___________________________________________
___________________________________________
ii The arithmetic sum of the branch current and the
measured value of total current.
I
___________________________________________ Cos  2
 .......... ........ 
__________ I
1
136 Power: Wireman (NSQF Level - 4) Exercise 1.7.50
TASK 7 : Determine the characteristics of R-L-C in parallel circuits
1 Form the circuit as shown in Fig 7. Conclusion
2 Repeat steps 2 to 13 of TASK 2 and record the readings i Effect of change of supply voltage in R-L-C parallel
in Table 8. circuit as regards power factor of circuit.
3 Compare the readings of the power factor in all the ___________________________________________
cases. Record your observations.
___________________________________________
ii Effect of change in capacitance in RLC parallel circuit.
___________________________________________

Table 8
Sl. V Volt I Amp. W AP = V xI W P.F. Meter Capacitor
No. True power Apparent power Cos  reading value in
AP
in Watt in VA FD

1 100 V 4
2 200 V 4
3 200 V 0
4 200 V 2
5 200 V 3

__________

Power: Wireman (NSQF Level - 4) Exercise 1.7.50 137

Power Exercise 1.7.51
Wireman - Magnetism and Capacitors - AC Circuits

Verify the relationship between Line and Phase values in 3 phase star and
delta connections
Objectives: At the end of this exercise you shall be able to
• verify the relationship between Line and Phase values in star connection
• verify the relationship between Line and Phase values in delta connection.

Requirements
Tools and Instruments/equipment Materials
• Screw driver 150 mm - 1 No. • Connecting leads - as reqd.
• Combination plier 150 mm - 1 No. • Lamp BC - 40W 240V - 6 Nos.
• M.I Ammeter type 0-1 amp - 2 Nos. • 100W 240V - 6 Nos.
• M.I Voltmeter type 0-500V - 2 Nos. • 200W 240V - 6 Nos.
• ICTPN switch 16A 500V - 1 No.

PROCEDURE
TASK 1: Verify the relationship between Line and Phase values in star connection of three phase system
1 Form the circuit as per the given circuit diagram. 7 Measure the Line and Phase current and enter the
(Fig 1) with one lamp each connected to all the 3 readings in Table 1.
phases (40/100/200 W).
Switch ‘OFF’ supply before effecting any
2 Identify the 3-phase (L1, L2, L3) and neutral (N) of supply change in load.
terminals.
8 Repeat steps 3 to 7 for different loads.
3 Switch ‘ON’ the 3-phase supply.
9 Calculate the ratio between the Line voltage and Phase
4 Measure the line voltage VUV by placing the voltmeter voltage.
leads between the two lines and enter the reading in
Table 1. VUV

5 Repeat for the other line voltages VVW, VWU. VUN
6 Measure the phase voltages by placing the voltmeter
leads between one line and star point N, and enter the VVW

readings in Table 1. VVN

VWU

VWN

10 Verify the ratio between Line current and Phase current,

i.e.

ILU ILV ILW

  
IPU IPV IPW

11 Get it checked by the instructor.

138
 Table 1
Sl. No. Load in watts Line voltage Phase voltage Line current Phase current
per phase
VUV V VW V WU VUN VVN V WN IU IV IW I UN I VN I WN

1 40W

2 100W

3 200W

__________
TASK 2: Verify the relationship between Line and Phase values in delta connection in three phase system

1 Form the circuit as per the given circuit diagram. 4 Record the Line voltages and Phase voltages measured,
(Fig 2) Two lamp in series to be connected between under the appropriate column in Table 2.
two phases of same voltage.
5 Measure the Line and Phase currents and enter the
readings in Table 2.
An ammeter connected between supply and
load indicates Line current. An ammeter
connected in series with single load (two lamps
in series) indicates Phase current.
6 Repeat steps 2 to 5 for different loads.
Switch off the supply before effecting any
change in the load.
7 Verify the relationship between Line and Phase value
of current and voltage. Enter in Table 3.
Result
2 Switch ON the 3-phase supply. Measure the line
In star : Line current and Phase current are
voltages by connecting the voltmeter leads between
two of the terminals U1, V1, W1. whereas Line voltage = x Phase voltage.
3 Measure the phase voltage by placing the voltmeter In delta :Line voltage and Phase voltages are
leads across the lamps, i.e. U1, U2 or V1, V2 or W1, W2.
whereas Line current = x Phase current.
8 Get it checked by the instructor..
Table 2
Sl. No. Load in watts Line voltage Phase voltage Line current Phase current
per phase
VU1V1 VV1W1 V W1U1 VU1U2 VV1V2 V W1W2 IU IV IW IU1U2 IV1V2 I W1W2

1 40W

2 100W

3 200W

Table 3

VU1V1 VV1W1 VW1U1 ILU ILV ILW

Load
VU1U2 VV1V2 VW1W2 IPU IPV IPW

40W

100W

200W
__________
Power: Wireman (NSQF Level - 4) Exercise 1.7.51 139
Power Exercise 1.7.52
Wireman - Magnetism and Capacitors - AC Circuits

Measure the current, voltage, power and power factor in single and poly- phase
circuits
Objectives: At the end of this exercise you shall be able to
• measure current, voltage, power and power factor in single phase circuit
• measure current, voltage, power and power factor in poly-phase circuit.

Requirements
Tools and Instruments Equipment/Machines
• Insulated screw driver 200mm - 1 No. • 3 Induction motor 2kw/415V - 1 No.
• Insulated combination plier 200 mm - 1 No. • 1 Induction motor 0-75 HP - 1 No.
• MI Voltmeter 0-300V/600V - 1 No.
Materials
• Wattmeter 250V/500V, 5A/10A - 3 Nos.
• Power factor meter 250V/500V, 5A - 1 No. • PVC Insulated copper cable 2.5 mm2
• MI Ammeter 0-10A - 1 No. 1.1 KV grade - 20 mtrs.
• 3KW/3 Phase lamp load - 1 No.

PROCEDURE
TASK 1: Measure current, voltage, power and power factor in single phase circuit
1 Select and collect the proper range of instruments and 5 Switch 'ON' the lamp load switch one by one.
lamp load of phase motor for 10 circuit.
6 Record the meter readings and enter in Table 1 of each
2 Connect the meters and lamp load as per the circuit steps.
diagram.
7 Replace lamp load and connect 10 induction motor.
Connect the current coils of wattmeter and PF
8 Switch 'ON' the motor load and record the meter
meter in series with the load.
readings in Table 1.
3 Switch 'ON' the power supply and observe the meter
9 Get it checked by the instructor.
deflections.
4 Note down the meter readings and enter in Table 1.

140
 Table 1
Sl. Load Voltmeter Ammeter Watt meter P.F
No. reading reading reading meter
in volts MI volts reading
1 No load
2 400W
3 600W
4 800W
5 1000W
6 1 motor
__________
TASK 2: Measure current voltage, power and power factor in poly phase circuit

1 Select and collect the proper range of instruments, lamp 5 Switch 'OFF' the power supply.
load and induction motor for AC 3 phase circuit.
6 Replace lamp load and connect 3 induction motor
2 Connect the meters and lamp load as per the circuit as the load.
diagram.
7 Switch ON the power supply and ascertain the motor
Connect the current coil of wattmeter and running.
power factor meter in series with load.
8 Record the meter readings in Table 2.
3 Switch 'ON' the power supply and observe the meter
9 As the wattmeter reading indicates the power of one
deflections.
phase total power is 3 times of wattmeter reading.
4 Note down the meter readings in Table 2.
10 Get it checked by the instructor.

Table 2
Sl. Load Voltmeter Ammeter Watt meter Total P.F meter
No. Reading Reading Reading Power Reading
VL1 IL Wx3

1 Lamp load

2 Motor load

__________

Power: Wireman (NSQF Level - 4) Exercise 1.7.52 141

Power Exercise 1.7.53
Wireman - Magnetism and Capacitors - AC Circuits

Measurement of energy in single and poly-phase circuits

Objectives: At the end of this exercise you shall be able to
• connect voltmeter, ammeter, wattmeter power factor meter and 3 phase energy meter in 3 phase circuits
• measure the voltage, current, power and power factor and 3 energy in 3 phase circuits with lamp load
• measure the voltage, current, power and P.F and energy in 3 phase circuits with inductive lead (Induction
motor).

Requirements
Tools and Instruments/equipment Equipment/Machines
• Insulated screw driver 200 mm - 1 No. • 3-phase induction motor 415V, 50 Hz,
• Insulated cutting plier 150 mm - 1 No. 5 HP (3.75 KW) - 1 No.
• M.I Voltmeter 0-300V/600V - 1 No. • 3-phase lamp load 100 W - 6 Nos.
• M.I Ammeter 0-5A/10A - 1 No.
Materials
• Wattmeter 250V/500V, 5A/10A - 1 No.
• Power Factor meter 415V/20A - 1 No. • PVC insulated copper cable
• 3 phase 4 wire energy meter 415V/20A - 1 No. 2.5 mm2 650V grade TPIC 16A/500V - 20 m.
• 200 Watt/250V, lamps - 6 hrs.

PROCEDURE
TASK 1: Measure three phase current, voltage, power and power factor in 3 phase circuit with lamp load
1 Select and collect the proper range of meters and lamp 2 Make the connections of the meters and load as per
load for 3 phase circuit. the circuit diagram (Fig 1).
The lamp load should have equal wattage inall Connect the current coils of wattmeter, energy
three phases meter and P.F meter in series with the load.

3 Switch ‘ON’ the power supply momentarily after getting 6 Keep the load in ‘ON’ position for at least 10 minutes
the approval of the instructor and observe all themeter and then note and record the final reading and calculate
deflections. Keep the switch closed if nothing is the energy consumption (i.e) F.R - I.R.
abnormal.
7 Swtich ‘OFF’ the power supply.
4 Note down the initial reading of the energy meter.
8 Replace the 100 Watt lamp with 200V lamp load.
5 Note down the meter readings and enter in Table 1.
9 Repeat steps 3 to 6 and record the readings in Table 1.

142
 Table 1
Load Line Phase Line Phase Power Power Initial Final Energy
Voltage Voltage Current Current in factor reading reading consumption
VL Vph IL IPH watt in energy after 10 F.R. - I.R
meter min in in KWh
energy
meter F.R
Lamp
load
for
100W
Lamp
load
for
200W
3
Ind.
meter
load

10 Switch ‘OFF’ power supply and disconnect the lamp 11 Repeat steps 3 to 6 and record the readings in Table 1.
load and connect 3 phase induction motor 3.75 KW/
12 Get it checked by the instructor.
4.5V/50 Hz to the circuit.

__________

TASK 2: Measurement of energy with lagging and leading P.F.

1 Identify the energy meter terminals - line and load, after 4 Note the meter constant from the nameplate of the
removing the terminal cover. energy meter. (Fig 3)
Always mount the meter vertically.
2 Associate the circuit diagram (inside) with the terminal
markings of the instrument.
3 Connect the energy meter terminals (line and load) in
the circuit as in Fig 2.

5 Record the initial meter readings.

6 Switch ON the circuit with load.
7 Record the reading after 30 minutes in Table 2.

Power: Wireman (NSQF Level - 4) Exercise 1.7.53 143

 Table 2

SI. No. Volt Current Meter constant Time Energy

(V) (I) in revolution (secs)
Wh Wh
(Measured) (Calculated

8 Connect the inductive load (Lagging power factor) and 9 Calculate the energy for lagging PF.
record the reading (Fig 4) in Table 3.

Table 3

SI. No. Volt Current W Meter constant Time Energy

(V) (I) in revolution (secs)
Wh Wh
(Measured) (Calculated

__________

144 Power: Wireman (NSQF Level - 4) Exercise 1.7.53

Power Exercise 1.7.54
Wireman - Magnetism and Capacitors - AC Circuits

Use of phase sequence meter

Objectives: At the end of this exercise you shall be able to
• connect the phase-sequence meter and identify the sequence.

Requirements
Tools and Instruments/equipment Materials
• Phase-sequence meter - 1 No. • Connecting leads - 3 Nos.

PROCEDURE
1 Read the marking on the phase sequence indicator
and record the direction for
RYB sequence
RBY sequence
PHASE SEQUENCE
In the direction of arrow on disc: ________________
Opposite to the direction of
arrow on disc: ______________________________
2 Switch OFF the supply and connect the 3 phases of
the supply to the sequence indicator. (Fig 1)
Mark the leads as I, II, III. Connect them, such that I is
connected to R, II to Y, III to B.
You can connect any lead (phase) to any
terminal in the sequence indicator.
3 Switch ON the supply and observe the direction of the
disc movement.
4 Record the direction by a tick mark.
5 If the rotation is opposite, switch OFF the supply and
interchange the leads II & III connected to the terminals
Y and B. Switch ON the supply. 6 Now the disc will rotate in the direction of the arrow.
7 Mark the leads corresponding to the letters on the phase
sequence indicator.
__________

145
Power Exercise 1.8.55
Wireman - Earthing

Practice on Earthing – different methods of earthing

Objectives: At the end of this exercise you shall be able to
• prepare the pit pipe for earthing
• install the earth pipe and test it
• prepare the pit plate for earthing
• install the plate in earthing pit.

Requirements
Tools and Instruments/equipment Materials
• G.I. die stock with 12.7 mm, 19mm • G.I. pipe 12.7mm dia - 10 m.
and 38mm dies - 1 Set. • G.I. bend 12.7mm dia - 4 Nos.
• D.E. spanners 5mm to 20mm - 1 Set • C.I. cover hinged to C.I. frame 300mm - 1 No.
of six. • G.I. plate 600x600x6.3 mm - 1 No
• Blowlamp, 1 litre with kerosene - 1 No. • G.I. pipe 19mm dia - 1 m.
• Crowbar, hexagonal 1800mm long - 1 No. • G.I. pipe 38mm dia. having 12mm
• Powrah (spade) - 1 No. dia holes - 5 m.
• Pick axe - 1 No. • Reducer 38 x 19 mm - 2 No.
• Cement mortar tray - 2 Nos. • Funnel with 19mm dia. sleeve &
• Tongs 300mm - 1 No. wire mesh - 2 Nos.
• Measuring tape 5m - 1 No. • G.I. nut for 19mm dia. sleeve & wire mesh - 2 Nos.
• Ladle - 2 Nos. • G.I. check-nuts for 19mm dia. G.I. pipe - 6 Nos.
• Combination pliers 200mm - 1 No. • G.I. washer 40mm with 19mm hole - 3 Nos.
• Pipe wrench 50mm - 1 No. • G.I. wire No.8 SWG - 2 m.
• Hacksaw with 32 T.P.I. blade - 1 No. • Copper lug 200 amps with 19mm dia. hole - 2 No.
• Wooden box 150 (I) x 150 (b) x • Solder 60/40 - 200 gms.
300(h) mm - 1 No. • Matchbox - 1 No.
• Soldering pot (melting) - 1 No. • Soldering paste - 50 gms.
• Cement - 20 gms.
• Blue metal chips 6mm size - 50 gms.
• River sand - 160 kgs.
• Salt (common) - 10 bags.
• Coke or charcoal - 10 bags.

PROCEDURE
TASK 1: Prepare and install pipe earthing
1 Collect G.I. pipes and the accessories. 7 Dig an earth pit of dimensions 1 m width x 1 m breadth
x 3.75 m depth.
2 Make a slant cut of 30º in the 38mm dia. G.I. pipe to
have sharp edge as in Fig 1. The depth given here is the minimum
recommended. However, the depth may be
3 Make threads in the other end of 38mm dia. G.I. pipe
increased till moist soil is reached.
to a length of 25mm.
8 Place the fabricated pipe in an upright position as in
4 Make threads in both ends of 19mm dia. G.I. pipe to a
Fig 1 and position the pipe with the help of bamboo
length of 25mm on one side and 75mm on the other
sticks.
side.
9 Place the wooden box around the pipe and fill it to a
5 Fabricate the 38mm and 19mm dia. G.I. pipes as in
height of about 15cm with charcoal, and fill the
Fig 1.
surrounding outer space of the box with soil.
6 Select an earth pit site atleast 1.5 metres away from
It is difficult to dig a pit 150mm square. A pit of
the building foundation.
dimension 1 metre square is therefore
An earth electrode should not be installed in suggested to be dug. The area sufficient to be
proximity to a metal fence to avoid the filled with salt and charcoal is about 150mm
possibility of the fence becoming live. If the square. Hence fill the surrounding extra area
metal fence is unavoidable, it should be with the soil which was taken out earlier.
earthed.
146
 10 Lift and place the wooden box above the coke layer.
Fill up with salt to a height of about 15cm and to an
area of 150 x 150mm area around the pipe.
Fill up the surrounding area with soil.
11 Repeat the above steps 10 and 11 up to 2.5 metres as
in Fig 1.
12 Place the G.I. pipe 12.7 mm dia. meter with G.I. bends
in proper position for E.C.C. connection.
13 Prepare the concrete mixture and build the structure
as in Fig 1.
14 Fix the G.I. cover also.
Atleast allow one day for curing the concrete
structure. Pour water every 2 hours. (A wetted
gunny sack will hold the moisture for several
hours.)
15 Insert the G.I. wire No.8 SWG through the 12.7mm
dia, G.I. pipe.
The size of the earth wire depends upon the
incoming supply cable size.
16 Use the ladle and the blow lamp and melt the solder.
17 Solder the lug in the G.I. wire.
18 Insert the lug in the 19mm dia. G.I. pipe and tighten it
with the G.I nut and check-nut.
19 Porur three or four buckets of water through the funnel.
Allow an hour for the water to be absorbed in
the earth.
20 Get it checked with your instructor.
__________
TASK 2: Prepare the plate for earthing and install the plate in earthing pit
1 Collect G.I. plate and accessories for earthing. Prepare the earthing pit in ground as per standard
2 Mark thread on one side of 19mm dia GI pipes to a 1 Select an earth pit site atleast 1.5 m away from the
length of 25mm. building foundation.
3 Fabricate GI plate as in Fig 2 600x600 square plate An earth electrode should not be installed is
with a thickness of 6.3 mm. proximity to a metal fence to avoid the
possibility of the fence becoming live. If the
metal fence is inavoidable it should be earthed.
2 Dig an earth pit of demensions 1m width x 1m breadth
1.5m depth.
The depth given here is the minimum
recommended. However the depth may be
increased till moist soil is reached.
3 Fabricate G.I. pipe 12.7mm diameter with GI bonds in
proper position and insert the G.I wire missing through
GI pipe by soldering lug at external and fix GI plate
with bolt and nut as in Fig 3.
4 Place the fabricated 19mm dia GI pipe in an upright
position as in Fig 3 and position the pipe with the helps
bamboo sticks.
4 Fabricate 19mm dia G.I. pipe as in Fig 3.

Power: Wireman (NSQF Level - 4) Exercise 1.8.55 147

 5 Place the wooden box around the plate and fill it to a
height of about 15cm with charcoal and fill the
surrounding outer space of the box with soil.
It is difficult to dig a pit 150mm square. A pit of
dimension 1 meter square is therefore
suggested to be dig. The area sufficient to be
filled with salt and charcoal is about 150mm
square. Hence fill the surrounding area with
the soil which was taken out earlier.
6 Lift and place the wooden box alove the coke layer and
fill up with salt to a height of about 15cm and ban area
of 150 x 150 mm area around the pipe.
Fill up the surrounding area with soil.
7 Prepare the concrete mixture and build the structure
as in Fig 3.
8 Fix the GI core with the plates.
At least allow one day for curing the concrete
structure. Pour after every 2 hours (A wetted
gunny is a act will hold the moisture for several
times.
9 Pan three a four buckets of water through the funnel to
the earth pit.
Allow the hour for the water to be absorbed in
the earth.

__________

148 Power: Wireman (NSQF Level - 4) Exercise 1.8.55

Power Exercise 1.8.56
Wireman - Earthing

Measurement of Earth resistance by earth tester

Objectives: At the end of this exercise you shall be able to
• measure the earth resistance using earth tester
• measure the resistance using three/four terminal earth tester.

Requirements
Tools and Instruments Equipment/Machines
• Screw driver 200mm - 1 No. • Earth tester 3/4 terminal - 1 No.
• Pipe wrench, 250mm long - 1 No.
Materials
• Straight pein hammer 15 kg - 1 No.
• Spanner set 5mm to 20mm - 1 No. • Test lamp with 16 watts bulb 230 V - 1 No.
• Metal spikes - 2 Nos.
• Standard cable - Set of 3

PROCEDURE
TASK 1: Measure the earth resistance using the earth tester
1 Drive the metal spikes at a distance of 15m each from
the earth electrode in a straight line as Fig 1.

4 Read the earth electrode resistance from the meter

and enter the same in Table 1.
However refer to the instruction manual 5 Take three more readings (Fig 5) by shifting the position
supplied with the earth tester and follow the of the spikes by 90º around the earth electrode under
instructions regarding the distance between test as in Fig 3.
the spikes and the earth electrode as well as
Table 1
the pattern i.e. straight or equilateral triangle.
Sl. Location Earth Actual value of elec
2 Connect three terminals of earth tester with the earth
No. electrode trode resistance
plate under test and metal spikes as in Fig 1.
resistance (Highest value out
In the case of a four terminal tester make the in ohms of the four readings)
connection as per circuit diagram Fig 2.
1
Use only the accessories (like spike and cables)
supplied along with the earth tester by the 2
manufacturer.
3
3 Rotate the generator handle at the rated speed until
the pointer comes to rest. 4

149
 If the electrode is near a wall of a building
atleast 3 readings could be taken by shifting
the spikes at 45º (Fig 3 and Fig 4)

__________

150 Power: Wireman (NSQF Level - 4) Exercise 1.8.56

Power Exercise 1.8.57
Wireman - Earthing

Testing of Earth Leakage by ELCB and relay

Objectives: At the end of this exercise you shall be able to
• identify the terminals of ELCB
• connect the ELCB in an electrical circuit and test its functioning
• measure the leakage current at which ELCB trips off.

Requirements
Tools and Instruments Equipments/Machines
• Cutting plier 150mm - 1 No. • ELCB 240V, 25A, 2 pole with
• Screw driver 150mm - 1 No. Tripping leakage current 30mA - 1 No.
• Electrician knife 100mm - 1 No. • MCB 240V, 10A, 2 pole - 1 No.
• Wire stripper 150 mm - 1 No.
Materials
• Ammeter MI (0 - 10A) - 1 No.
• Ammeter MI (0 - 100mA) - 1 No. • 10k 1W wire wound variable resistor - 1 No.
• 5k 1W fixed resistor - 1 No.
• Pushbutton switch 240V, 6A - 1 No.
• Water rheostat - 1 No.

PROCEDURE
TASK 1: Identify the terminals of ELCB
1 Collect the ELCB from your instructor and read the
specification given on it.
Identify the supply terminals and load terminals
referring the marking on the unit as given in
Fig 1.

__________
TASK 2: Connect and test the operation of ELCB
1 Wire up the circuit as in the circuit diagram. (Fig 2)
and get the approval from instructor.
2 Switch OFF the main supply keeping the MCB and
ELCB in ON position.
3 Close switch S1 and operate the water rheostat till the
ammeter A reads about 5 A current.
Keep variable resistance 'RS' in full cut in
position.
4 Press the test switch and vary the variable resistance
and note the leakage current and record __________
5 Record the leakage current at which the ELCB trips off
________________.
6 Open the external test switch and reset the ELCB.
7 Test ELCB for Trip function by operating the test button.
In this case the ELCB must trip off when the button is
pressed
151
Power Exercise 1.9.58
Wireman - Basic Electronics

Determine the resistance by Colour coding

Objectives: At the end of this exercise you shall be able to
• identify the types of resistors by referring to the pictorial representation
• identify the colour bands, and decode the resistance value
• calculate the tolerance value by the colour band
• measure the actual value with an ohmmeter verify with calculated value.

Requirements
Tools and Instruments/equipment Materials
• Multimeter/Ohmmeter - 1 No. • Various types of resistors (assorted
values) including potentiometers of
carbon track and wire-wound type. - as reqd.

PROCEDURE
TASK 1: Identify the type of resistor from pictorial representation

1 Identify the resistor type by referring Fig 1 and write

the type in Table 1.
2 Sketch the I.S. symbol for the identified resistor in
Table 1.

Table 1
Sl. No. Sketch reference Type of resistor Symbol
1 A
2 B
3 C
4 D
5 E
6 F
7 G
8 H
9 I

__________

152
TASK 2 : Identify the colour band and decode the resistance value
1 Identify the value of resistors in Fig 2 from the colour
bands and enter Table 2.

3 Write the 1st number and 2nd number in Table 2.

4 Identify the colour of the 3rd band and write the multiplier
value in the respective column in Table 2.
5 Compute the value of the resistor and record in
Table 2.
6 Identify the 4th band colour and fill up the tolerance in
Table 2.
7 Determine the resistance value and the tolerance for
the another given resistors and record in Table 3 by
repeating the above steps 1 to 6.

2 Identify the first two colour bands of the resistors given 8 Measure the value of the resistors by using a
by the instructor (in sequence commencing from the multimeter/ohmmeter and enter the values in Table 3
1st colour band closer to one end of the resistor - Refer by following the procedure given below.
Fig 3.
Table 2
Sl.No. Colour 1st No. 2nd No. 3rd No. Multiplier Resistance Tolerance

1st 2nd 3rd 4th

Band Band Band Band

A
B
C
D
E
F
G

a Connect the probes ii Maintain firm contact with the resistor lead wires
i Connect the red probe to the POSITIVE terminal
ii Connect the black probe to the COMMON terminal
b Set the multimeter/ohmmeter (Fig 4)
i Set the range selector switch to one of the ohm
range.
c Conduct zero ohm adjustment in analog
multimeter
i Short-circuit the two probes at the selected range.
ii Turn the ohm adjustment knob until the pointer is
set at zero ohm. (zero adjustment)
e Read the meter
d Connect the resistor to be measured.
i Use a range which deflects the pointer to middle of
i Keep your finger tips off from the probes. the scale (Fig 5)

Power: Wireman (NSQF Level - 4) Exercise 1.9.58 153

 iv In Fig 4, the resistance range x 100 is selected, if
so the value of the resistance is 15 x 100 = 1500
ohms = 1.5 (K Ohm)
9 Enter the marked value of resistance and tolerance
(by the colour band over the resistor) in Table 3.
10 Calculate the minimum and maximum values of actual
resistance for each resistor considering the tolerance
marked over it. (Table 3) Record the values in Table 3.
11 Determine the acceptability (OK or not OK) by
comparing the measured value with the minimum and
ii Read the meter in the Ohm scale right above the maximum of the indicated value.
pointer. (In this case 15 as shown in Fig 5)
Note : Each range selection zero adjustment is
iii Resistance = (Ohm scale reading) x (Magnification to be ensured for correct value of resistance.
at selected range of the resistance range).

Table 3
Sl.No. Band Recorded Tolerance Max. Min. Measured Remarks
resistancce in Ohm value of value of value OK or
1st 2nd 3rd 4th value resistance resistance not OK
Band Band Band Band

1
2
3
4
5
6
7
8
9
10

12 Report and get it checked by your instructor.

__________

154 Power: Wireman (NSQF Level - 4) Exercise 1.9.58

Power Exercise 1.9.59
Wireman - Basic Electronics

Identification of active and passive electronic components

Objectives: At the end of this exercise you shall be able to
• identify the electronic components - diode, diode bridge, transistor, SCR, IC by referring to the pictorial
representation
• identify the given electronic components- diode, diode bridge, selenium bridge, transistor, IC, by visual
inspection
• read the symbols for active components in the given circuit diagram
• identify the active components and their base diagram, lead configuration by referring to the data book by
component code number
• decode and name the semi conductor devices - diodes transistors, SCRs
• identify the passive components by visual inspection
• interpret the coding and marking on the components
• test the components for its working conditions.

Requirements
Tools and Instruments/equipment Materials
• Multimeters/Ohmmeter - 1 No. • Capacitors, inductors, resistors
(assorted size, shape and values) - as reqd.
• Assorted components of diodes,
transistors, SCRs, DIACs, TRIACs, UJTs,
FETs bridge diodes etc of different
types with semi-conductor data manual - as reqd.

PROCEDURE
TASK 1: Identify the active components

Assumption: Given components have their code Table 1

number, lead identification marks are Sl.No. Figure number Component's name
available in data book
1 Fig 1 a
1 Look at the Fig 1. Identify the component from the
pictorial representation. Give your response in Table 1. 2 Fig 1 b
3 Fig 1 c
4 Fig 1 d
5 Fig 1 e

Table 2
Sl.No. Figure number Component's name
1 Transistor with heat sink
2 Diode bridge
2 Write the figure Nos. that indicate the components given 3 Integrated circuit
in Fig 2, in Table 2
4 Diode
5 Transistor
3 Match the names and pictorial representations of the
active components (Fig 3).Record your response in the
space provided.
4 Collect the electronic (ACTIVE) components from your
instructor. Identify the components and record your
response in your record book along with sketches of
the components. (Refer Fig 3 for guidance)
155
5 Identify the electronic components from the given circuit
diagram Nos 4,5 and 6 and write the names of the
components in the Table 3.
6 Decode and name the semiconductor devices from their
letter designation given in Table No.4 with the help of
the data book. Reproduce the base diagram with a clear
sketch in Table 5.
7 Identify the leads by decoding the marking in the base
diagram in the data book for the semiconductor devices. 8 Get it checked by your instructor.

156 Power: Wireman (NSQF Level - 4) Exercise 1.9.59

 Table 3 Table 3
Sl. No. Labels Components Component's Sl. No. Code No. of Component's
names symbol components name

1 A 1 OA79
2 B 2 DR25
3 C 3 IN4007
4 D 4 AA119
5 E 5 BY127
6 F
6 BZ148
7 G
7 BC147
8 H
8 2N904
9 I
9 BD115
10 J
10 BFW10
Table 5
11 3N187
Sl.No. Code No. Base diagram
12 BTY87
1 IN4007
13 2N2646
2 SL100
14 D3202Y
3 BC147
15 T2801B
4 2N5296
16 CA741
5 2N3035
6 SN204 17 CA723

7 2N2646 18 NE555

8 3N187
__________
TASK 2 : Identify and check the passive components
Instructor shall select the resistors, inductors 5 Divide the passive components into separate groups
and capacitors so that, few can be visually as resistor, inductor and capacitor by their appearances
identified and other can be identified by coding (or) code references.
only. 6 Interpret, the code references of resistor and list them
1 Identify the passive components referring to Fig 1 and in Table 7.
write the type of passive component in Table 6. 7 Measure the value of resistance of each by multimeter
2 Sketch the appropriate symbol against the and record in Table 7.
corresponding type of passive components in Table 6. 8 Interpret the code references of capacitor and list them
3 Get your result corrected by your instructor. in Table 8.

4 Collect assorted size, shape and type of passive 9 Check the capacitor for charge and discharge by
components from your instructor. multimeter, and record the condition in Table 8 by
referring Fig 7.
Table 6
Sl. No. Fig alphabets Components Reasons for identifications Symbols Remarks
identified as
1 A
2 B
3 C
4 D
5 E
Power: Wireman (NSQF Level - 4) Exercise 1.9.59 157
Sl. No. Fig alphabets Components Reasons for identifications Symbols Remarks
identified as
6 F
7 G
8 H
9 I
10 J
11 K
12 L
13 M
14 N
15 O
16 P

Table 7
Sl. No. Coded reference Type of resistors and other details Measured value of resistor

1
2
3
4
5
6

In case of very low value of capacitors, 10 Interpret the code references of inductors/ coils /
multimeter may not show any deflection during transformers and list them in Table 9.
charge or discharge. Anyhow if the multimeter 11 Check the continuity of the coil and its tapping with
reading is infinity the capacitor has to be the multimeter and record the condition in Table 9.
considered as good in case of non electrolytic
There should not be any continuity between
capacitors.
coil and the core.
12 Get the above observation approved by your Instructor.
Table 8
Sl. No. Coded reference Type of capacitors and other details Condition of capacitor
1
2
3
4
5
6
Table 9
Sl. No. Coded reference Type of inductors /coils transformers and other details Condition of coil
1
2
3
4
5
6

158 Power: Wireman (NSQF Level - 4) Exercise 1.9.59

 __________

Power: Wireman (NSQF Level - 4) Exercise 1.9.59 159

Power Exercise 1.9.60
Wireman - Basic Electronics

Interpret and the diodes symbol - Test construct and test half wave rectifier
circuit
Objectives: At the end of this exercise you shall be able to
• read and interpret the diode symbols
• identify the terminals of a diode and test the diodes for its condition
• construct a half-wave rectifier
• determine the output DC voltage.

Requirements
Tools and Instruments/equipment • Step-down transformer 240V 24V 500mA - 1 No.
• Multi strand wire, Red, Blue 23/0.2
• Trainees kit - 1 No.
of 250V grade - as reqd.
• Soldering iron 25W 240V - 1 No.
• Base board - 1 No.
• Voltmeter MC 30V - 1 No.
(Laminated board 30x15x3mm)
• Multimeter 20K/1V - 1 No.
• Mains cord 3 core cable 23/0.2
Materials
of 250V grade - 1 No.
• Lug board general purpose 5 points - 1 No. • Nuts, bolts and washers - as reqd.
• Diode IN4007 - 1 No. • 3 pin plug 5 A 250 V - 1 No.
• Resistor 470 - 1 No. • Resin core solder 60/40 - as reqd.
• Semiconductor diode IN 4001 or IN 4007 - 1 No.
• Suitable connecting wires for brad board - as reqd.
• Diodes symbol chart - 1 No.

PROCEDURE
TASK 1: Read and interpret the diodes symbols
1 Read and interpret the different the diodes symbols Table 1
from symbol chart. Sl. Name of the Draw the
2 Identify the symbol for particular diode. No. diodes symbols

3 Draw the each diode symbol in Table 1. 1 Diode

4 Get it checked with your instructor. 2 Zener diode

3 Tunnel diode
4 Photo conductive diode
5 Light emitting diode (LED)
6 Gun diode
7 Socket diode

__________

TASK 2: Test and identify the diodes

1 Set the multimeter in ohms range (x1). Connect its If the voltmeter kicks back then mark the
leads to a M.C. voltmeter (0-3V), to find out the polarity terminal of the multimeter opposite to voltmeter
of multimeter output voltage. polarity.
In digital multimeter the marked polarity and 3 Connect the +ve marked terminal for the multimeter to
polarity of output voltage are the same. one terminal of the diode and other to the -ve and
2 Check the deflection of the voltmeter, if it indicates the observe the reading.
voltage, mark the terminal of the multimeter
corresponding to the voltmeter polarity.

160
 If the meter reads low resistance then the lead
of the diode connected to +ve marked terminal
of the meter is the ANODE and the other is
cathode. As shown in Fig 1a.
If the the meter does not deflect as in Fig 1b
then the lead of the diode connected to +ve
marked terminal for the multimeter is the
cathode and the other is anode.
If the meter reads low resistance for both
polarities the diode is short.
If the meter reads high resistance for both
polarities the diode is open.

__________
TASK 3: Construct and test half wave rectifier
1 Test the continuity of the primary and secondary Table 1
windings of the given transformer. Exchange, if found I Tranformer specfications
defective. Record the specifications of the given
transformer in the Table 1. Type of transformer Type of core
Rated primary voltage
2 Referring to Fig 1. Follow the order of steps given below; Rated secondary voltage Rated secondary
• Mount the tested transformer as shown in Fig 2 on current
BASE BOARD using suitable size nuts, washers II Experimental details
and bolts. Get it checked by your instructor. 1 Main supply voltage Vrms
• Mount the rectifier diode on lug board by soldering. 2 Secondary voltage V(rms) Vrms
(input to the rectifier)
• Solder the wire connection and the three core power
cord as in Fig 1a & Fig 1b. 3 Expected DC output Vdc volts
4 Measured DC output Vdc volts
3 Connect AC mains to the board and switch ON mains.
Measure and record the mains voltage and transformer 5 Difference of (3) and (4)
secondary voltage VS(rms) (AC input to rectifier) in the 6 Peak value of input Vs(peak) volts
Table 1. 7 Frequency of input signal Hz
4 Calculate and record the expected DC voltage across 8 Peak volume of pulsating volts
load RL using the formula. DC Output
Vdc = 0.45 Vs(rms) 9 Frequency of pulsating Hz
DC Output
where Vs(man) is the AC input to the rectifier.
6 Record the difference in the calculated and measured
5 Measure and record the rectified DC voltage Vdc across values. Get it checked by your instructor.
load RL using multimeter.

__________
Power: Wireman (NSQF Level - 4) Exercise 1.9.60 161
Power Exercise 1.9.61
Wireman - Basic Electronics

Construct and test full wave rectifier ckt and bridge rectifier ckt
Objectives: At the end of this exercise you shall be able to
• construct and test a full wave rectifier using two diodes
• construct and test a bridge type, full wave rectifier using four diodes.

Requirements
Tools and Instruments/equipment Materials
• Trainees kit - 1 No. • Step-down transformer 240V, 12V-0-12V,
• Soldering iron 25W/250V - 1 No. 24VA - 1 No.
• Multimeter 20K/1V - 1 No. • Lug board general purpose 20 points - 1 No.
• Voltmeter m.c. (0 - 30V) - 1 No. • Base board - 1 No.
• Hook-up wires (red and back) - as reqd.
• Semiconductor diode, IN 4007
or Equivalent - 4 Nos.
• Resistance 470 - 1 No.

PROCEDURE
TASK 1: To construct and test a full wave rectifier
1 Check to confirm good condition of the given 2 Construct a full wave rectifier circuit as shown in the
components. Record specifications of the transformer schematic and layout diagram at Fig 1a & Fig 1b.
in Table 1.

162
 Table 1 4 Calculate the expected DC voltage Vdc across load RL
using the formula given below;
Transformer specifications
In full wave rectifier, Vdc = 0.9 Vs(RMS) where,
1 Rated primary voltage ---------- Vs(rms) is the voltage across the centre-tap and
2 Rated secondary voltage ---------- any one end terminal of secondary. Record the
between centre tape and value in Table 2.
one end 5 Measure the rectified output Vdc across RL and record
3 Rated secondary current ---------- it Table 2.
or VA rating transformer 6 Calculate and record the difference in the calculated
and measured Vdc values. Get it checked by your
3 Switch ON the circuit. Measure the AC input voltage
instructor.
Vs(rms) to the rectifier across the center-tap and any
one end of the transformer and record it in Table 2.

Table 2
Readings of two-diode full-wave rectifier
Vs(rms) Calculated Measured Difference of Peak value Frequency Peak value of Frequency
Vdc volts Vdc volts (2) & (3) of Vs of Vs pulsating Vdc pulsating Vdc
(1) (2) (3) (4) (5) (6) (7) (8)

__________

TASK 2: To construct and test a Bridge rectifier

1 Modify the two diode full wave rectifier wired in Task 1 3 Calculate the expected output DC voltage Vdc across
to construct a bridge rectifier, referring to the schematic load RL using the formula, In a brdige rectifier.
and layout diagrams shown in Fig 2a & Fig 2b.
Vdc = 0.9 Vs(rms) where, Vs(rms) is the AC input to the
2 Switch on the circuit. Measure and record the AC input rectifier (refer Fig 2). Record the value in Table 3.
Vs(rms) to the rectifier in Table 3.
Table 3
Readings of Bridge Rectifier
Vs(rms) Calculated Measured Difference of Peak value Frequency Peak value of Frequency
Vdc volts Vdc volts (2) & (3) of Vs of Vs pulsating Vdc pulsating Vdc
(1) (2) (3) (4) (5) (6) (7) (8)

Power: Wireman (NSQF Level - 4) Exercise 1.9.61 163

4 Measure the DC output Vdc across the load RL and 5 Record the difference in the calculated and measured
record it in Table 3. values in Table 3. Get it checked by your instructor.

__________

164 Power: Wireman (NSQF Level - 4) Exercise 1.9.61

Power Exercise 1.10.62
Wireman - Measuring Instruments

Measurement of voltage, current and resistance in different circuits

Objectives: At the end of this exercise you shall be able to
• identify single and multi-range scale instruments
• connect single and multi-range scale meters to the circuit and measure the current and voltage and verify
the readings
• measure the resistance by shunt and series type ohm meters
• practice in use of multimeter.

Requirements
Tools and Instruments • Rheostat 200 ohms 3.7 amps - 1 No.
• Multimeter - 1 No.
• Round nose pliers 200mm - 1 No.
• Voltmeter MC 0-300V - 1 No. Equipments/machines
• Voltmeter MC multirange
• Lamp load 2-3kW 240V - 1 No.
0-75-150-300V - 1 No.
• Resistors (assemble sizes) - as reqd.
• Ohm meter shunt type & series type - 1 No
• Connecting leads - as reqd.
each.
• Millivoltmeter (any range) - 1 No. Materials
• Milliammeter (any range) - 1 No.
• PVC insulated copper cable
• Ammeter MC 0-5A - 1 No.
3/0.91 of 65V grade - 5 m.
• Ammeter MC of multi-range 0-1-2.5-5A - 1 No

PROCEDURE
TASK 1: Identifying the instrument
1 Identify the given instruments from the dial and terminal 2 Write the specifications of the instruments in Table 1.
markings and enter your findings in Table 1.
Table 1
Sl. Instrument Function Used in AC or DC Range Scale
No. Sl.No. or AC and DC
Symbol Description Single Multi- Single Multi- Specifi
Symbol Description Range Range cation

1
2
3
4
5
6

__________
TASK 2: Measure the current by using single and multirange ammeters

1 Connect the ammeters with the lamp load as in Fig 1 Take the reading on A2 at 3 different range by
and keep the variable arm of the potential divider at switching off and changing the connection.
minimum position.
3 Repeat the same by adding loads L2 and L3 one by
2 Switch ON the main supply and load L1. Adjust the one and record the values of current in Table 2.
supply voltage to 200V and record the value of current
in ammeter 1 & 2 of the circuit in Table 2. Limit the maximum current in the circuit to one
Amp.

165
 Table 2
Sl. No. Connected lamp I1 I2 Multi-scale/range ammeter
Load 0-5A
0 - 1A 0 - 2.5A 0 - 5A

1 L1

2 L1 & L2

3 L1, L2 & L3

4 Switch OFF the supply and compare the readings. Take the reading of V2 at each by switching off
5 Connect the voltmeters with supply as in Fig 2. and changing the connection.

Keep the variable arm of the potential divide 7 Vary the rheostat for the required voltage and record
at minimum position to obtain minimum value values of voltage V1 and V2 in Table 3.
age. 8 Switch OFF the supply and compare the voltmeter red
6 Switch ON the main supply and adjust to red voltage adjusted voltage V1 ,V2 multi-scale/range voltmeter.
as in Table 3 and record the value voltage V1 and V2.

Table 3
Sl. No. Adjusted voltage V1 V2 Multi-scale/range voltmeter
by rheostat 0-300V
75 V 150 V 300 V
1 50 V

2 70 V

3 100 V

4 140 V

5 200 V

166 Power: Wireman (NSQF Level - 4) Exercise 1.10.62

Write your conclusion by completing the sentences. 2 For quality measurement is better to select a
_______________ range rather than a ____________
1 While reading multi-scale meters, check the range
range.
position from the _________________ switch or from
selected range from the __________________________
and also the corresponding ____________________
to read correctly. (Scale, range, connections).
__________
TASK 3: Measurement of resistance using a series type ohmmeter
1 Identify and collect a series type ohmmeter.
A series type ohmmeter will have zero reading
on the right side of the scale as shown in
Fig 3a.
2 Insert/connect the test leads/probes to the ohm
terminals.
3 Connect the test leads/probe ends together (short in
Fig 3b).
4 Adjust the meter deflection, exactly to full scale (zero)
as in Fig 3a by adjusting the zero-adjust control.
If the zero setting is not obtained, replace the
battery cell a new one.

7 Note down the scale reading and record in Table 4.

Table 4
Sl.No. Measured Multiplied by Value of the
value the range resistance
1
2
3
4
5
6

In some types of ohmmeters, the measuring

range is increased by incorporating a higher
voltage battery - with help of a range switch
as in Fig 3.
To change the range switch, do not forget to
adjust the meter to the zero position.
While using the range switch to determine the
actual resistance, multiply the meter reading
with the constant marked in the range switch.
8 Repeat the working steps 5 and 6 for measuring
different resistors (atleast 6 Nos.)
The highest accuracy is obtained at or above
the centre of the scale. Note that 'no deflection
5 Verify the scale reading and also note the values of of the pointer' corresponds to an open circuit.
major and minor divisions on the scale. 9 Show the readings to your instructor and get them
6 Connect the test leads/probes across the resistance approved.
be measured as in Fig 4.
__________

Power: Wireman (NSQF Level - 4) Exercise 1.10.62 167

TASK 4: Measurement of resistance using a shunt type ohmmeter
1 Identify and collect a shunt type ohmmeter.
A shunt type ohmmeter will have zero reading
on the left side of the scale as in Fig 5a shunt
type ohmmeters are used to measure low
resistance values only.
2 Keeping the test terminals open, presss the switch on
the meter and adjust the deflection exactly to full scale
(infinity) as in Fig 5a&5b by adjusting the control knob.
3 Check the cell/battery so that a full scale deflection is
obtained while pressing the switch.

Note that a push-switch is necessary to keep

the battery from running down when the
instrument is not in use. 8 Determine the value of resistance (deduct the leading
resistance from the resistance value measured).
4 Short the test leads as in Fig 6a and measure the lead
resistance as in 6b. Do not press the switch for a long time. It drains
the cell/battery.
5 Record the reading in Table 5.
9 Repeat the working steps 6 to 8 for measuring various
6 Connect the test leads across the resistance to
resistors (atleast 6 resistors).
measured as in Fig 7.
10 Submit the readings to your instructor and get the
7 Press the meter switch and record the meter reading
approved.
Table 5.

168 Power: Wireman (NSQF Level - 4) Exercise 1.10.62

 Table 5
*Lead resistance = .....................ohms
Sl.No. Measured Multiplied Actual value of the resistance =
value by measured value - *Lead resistance

__________

TASK 5: Measurement of resistance using a multimeter

1 Prepare the resistor boards using the tag board with
resistors as in Fig 8.

2 Collect the multimeter. (Fig 9)

Identify and investigate the use of the function 5 Plug the back test lead in the common jack and the
switch, range switch, dial marking, terminals lead in the positive jack.
before using the meter. Note, Fig 9 is for a 6 Short the ends of the two testing leads to check the
particular make multimeter given for your error in resistance mode.
guidance. If you are using a multimeter for the
first time it is always better to read the 7 Adust the zero ohm's control (zero adjustment) until
instruction manual thoroughly, atleast twice the pointer indicates zero ohm.
before using the meter. If the pointer cannot be adjusted to zero, the battery
3 Set the selector switch in the resistance position. must be replaced.

4 Set the selector switch to a suitable of multimeter 8 Open the shorted ends of the prods.
resistance range position. Do not keep the ends shorted for a long time,
Try to ascertain the approximate vaoue of the avoid draining of the batteries. Before
resistance from your experience. If the value measuring the resistance of the resistor which
cannot be ascertained set the range switch to is (in laid) in the circuit, see that the power
R x 100 and measure the resistance. If the supply try the circuit is switched OFF. In the
reading is not within the readable area of the case of circuit having electrolytic capacitors,
scale either try R x 1 or R x 1000. Make the they should be discharged before attempting
pointer to indicate just in the middle of the to measure resistance.
scale which will be having less error. Every 9 Connect the testing leads to terminal positions OFF A
time you change the range switch, the meter ss in Fig 8.
must be adjusted for zero.

Power: Wireman (NSQF Level - 4) Exercise 1.10.62 169

10 Note the reading in the ohm's scale and reacord e.g. If the meter reading is 4 when the range switch is in R
Table 6. x 100 position then the resistance value = 4 x 100 =
400 ohms.
11 Calculate the actual value of resistance taking
consideration the multiplying factor. 12 Repeat the steps from 8 to 10 for OB, OC and positions.

Table 6
Resistane measurement
Sl.No. Measurement points Selected Ohm's range Meter reading Actual value
(M.R.) M.R. x range

1 O -A

2 O-B

3 O-C

4 O-D

__________

170 Power: Wireman (NSQF Level - 4) Exercise 1.10.62

Power Exercise 1.10.63
Wireman - Measuring Instruments

Measurement of electrical power and energy by direct and indirect

Objectives: At the end of this exercise you shall be able to
• connect a voltmeter and ammeter in a DC circuit to measure power
• determine the power consumed by a component/circuit by the indirect method (using voltmeter and ammeter
• identify the terminals and connect a wattmeter in a circuit
• measure power consumed using a wattmeter (Direct method)
• measure single phase power by direct and indirect method
• measure the single phase energy by direct and indirect method.

Requirements
Tools and Instruments Equipments/Machines
• Wireman's took kit - 1 Set. • Heater 240 V - 1000 W - 1 No.
• Voltmeter 0-300V MC and MI - 1 No. • DC power supply 220 V 5 A - 1 No.
• Ammeter 0-5A MC and MI - 1 No.
Materials
• Wattmeter 250 V, 0-5A-10A
(Dynamometer type) - 1 No. • PVC insulated copper cable of
• Single phase wattmeter 250V-5A/10A 2.5 sq.mm, 660 V grade - 4 mtrs.
(Induction type) - 1 No. • SPDT knife swtich 16 A - 1 No.
• Single phase energy meter 250V/5A • ICDP switch 16 A 240 V - 1 No.
(Induction type) - 1 No • Lamps 200 W, 240 V - 2 Nos.
• Lamp 100 W, 240 V - 2 Nos.
• Lamp-holder BC - 4 Nos.

PROCEDURE
TASK 1: Power measurement - Indirect method
1 Connect the voltmeter, ammeter, load, switches and In the DC generator, the output supply could
fuses as in Fig 1. be adjusted. Take the help of your instructor.
4 Take readings of the meters and record the values in
Table 1.
5 Switch 'ON' the heater circuit by the help of the change
over switch.
6 Read the meters and record the readings in Table 1.
7 Open the main switch and disconnect the of elements.
8 Calculate the power using the formula.
Power = voltage x current
P = V x I watt
9 Record the value in Table 1.
2 Take the change-over switch in lamp load position.
Indirect power measurement is suitable of DC
3 Switch 'ON' the supply, and adjust the incoming voltage circuits and pure resistive AC circuits only.
to 220 V.
Table 1
Types of load Indirect method Direct method
Reading Reading Calculated Reading Multiplying Actual
of Voltage of Current power of watt- factor power
(V) (A) P=VxI watts meter (W) (MF) P=WxMF
Amp load
Water
__________
171
TASK 2: Powre measurement - Direct method
1 Identify the terminals of the wattmeter. 6 Check whether the voltmeter and ammeter readings
2 Determine the multiplying factor by analysing the dial, are the same as in Task 1.
maximum power marking, voltage and current ranges If variation is found get the power supply
of the wattmeter. adjusted in the source (DC generator) by your
3 Connect the voltmeter, ammeter, wattmeter, loads, and instructor.
switches as in Fig 2. 7 Read the wattmeter and record it in Table 1. (As the
voltmeter, ammeter readings are the same as in
Task 1, these need not be taken).
8 Repeat steps 5 and 6 of Task 1, open the switch and
disconnect the circuit elements.
9 Calculate the actual power by multiplying the
wattmeter reading by the multiplying factor and record
it in Table 1.
10 Compare the power calculated by the indirect method
with that of the actual power through the direct method.
11 Write the conclusion based on the comparison.
Conclusion

4 Keep the change-over switch in the lamp load position. ___________________________________________

5 Switch 'ON' the supply. ___________________________________________

___________________________________________
__________
TASK 3: Measure power in a single phase circuit directly and indirectly
1 Investigate the voltage and current rating of the current
coil and pressure coil terminals of the induction type
wattmeter.
2 Determine the magnitude of the load which can be
connected to the wattmeter circuit.
3 Connect the voltmeter ammeter and wattmeter and load
as in Fig 3. Let the load be 500 watts.
4 Close the switch and read the meters and record the
values in Table 1.
5 Open the switch.
7 Calculate the power (Direct method) by using the
6 Calculate the power (Indirect method) by using the formula = wattmeter reading x multiplying factor
cos = 1, for resistive load).
formula = V x I x cos ( applyied.

Table 1
Sl.No. V (Volts) I (Amps) Indirect method Direct method Lamp bank (load)
Power in watts (W) = wattmeter
V x I Cos(Cos= I) reading x MF
500 W
800 W
1000 W

8 Repeat the experiment for 800 W and 1000 W load Conclusion

and note down the values in Table 1.
___________________________________________
9 Open the switch and disconnect the circuit.
___________________________________________
10 Get it checked by your instructor.
___________________________________________
__________
172 Power: Wireman (NSQF Level - 4) Exercise 1.10.63
TASK 4: Measurement of single phase energy by direct method
1 Identify the energy meter terminals - line and load, after
removing the terminals cover.
Always mount the meter vertically.
2 Associate the circuit diagram (inside the terminal cover)
with the terminal markings of the instrument.
3 Connect the energy meter terminals (line & load) as
per the circuit as in Fig 4.

5 Record the initial meter reading in Table 2.

6 Switch ON the circuit with the load.
7 Record the rading after 30 minutes in Table 2.

4 Note hte meter constant from the name-plate of the 8 Calculate the energy consumed which is the difference
energy meeter (Fig 5) and record it in Table 2. between the present and previous readings and read it
in Table 1.
Load current should not exceed the rated
current of the energy meter. 9 Repeat the steps from 5 to 8 for three different values.

Table 2
Meter constant ................ Rev/kWh
Sl.No. Type of load Initial Final Energy
reading (IR) reading (FR) consumed (FR-IR)

__________
TASK 5: Measurement of energy by indirect method
1 Select a suitable range voltmeter and ammeter. 3 Close the switch in the circuit.
2 Connect the ammeter and voltmeter to the line and 4 Start teh stopwatch.
load as in Fig 6.
5 Observe the readings of the voltmeter and ammeter.
Watch the instruments constantly. No change
in the reading should take place during the
period of measurement.
6 Record the reading and time in Table 3 after 30 seconds.
7 Calculate the energy in watt-seconds with the given
formula.

Power: Wireman (NSQF Level - 4) Exercise 1.10.63 173

 Energy - V x I x Cos x t = watt seconds Table 3
Where V = voltage, I = current and t = time in Voltage Current Time in Energy in
seconds. Cos is the power factor which is seconds watt seconds
assumed to be unity as the load is pure
resistive. (V) (I) (t) (ws)

8 Repeat the steps 3 to 7 for 60 seconds and 90 seconds

time and record the values of the ammeter, voltmeter
and time. Calculate the energy consumption.

__________
TASK 6: Verify the calculated energy with the meter reading - (disc rotation)

1 Connect the instruments as per the circuit diagram in 8 Record the No. of revolutions (N) and the time in
Fig 7. Table 4.
9 Energy recorded is calculated by using the following
formula

N
Energy recorded  kWh
Meter Constant

N
i.e. Energy  kWh
2 Close the switch S. Meter Constant

3 Observe whether the voltmeter, ammeter readings are (kWh = 1000 x 3600 Watt second)
steady while the bulb is glowing. 10 Calculate the energy from the meter reading using the
4 Watch the rotation of the disc in the energy meter. formula.
5 Record the meter constant (number of revolutions per Energy = V x I x Cos x t Watt seconds
kWH from the dial mark on the disc.) (Where Cos is assumed for the in candescent load as
If the meter constant i.e. rev.per kWh is very
high in the order of 1000 and above, reduce V  Cos x I  t
Energy  kWh
the load suitably to avoid strain in counting. 1000  3600
6 When the red mark on the disc pass the window, start 11 Compare the direct reading of energy with the indirectly
the stopwatch to count the time, as well as start measured energy (calculated).
counting the number of revolutions of the energy meter
disc. 12 Repeat the steps 10 to 12 for the following values of
Watch there is no change in the readings of N = 1/5 of meter constant
the voltmeter and the ammeter. N = 1/4 of meter constant
7 On completion of 1/10 of the meter constant or N = 1/3 of meter constant
equivalent to the whole number of revolutions, stop the
stopwatch and switch OFF the supply. The vaue of N calculated from the meter constant
rounded off to the next higher value.
Table 4
Sl. Voltmeter Ammeter Time in Calculated Rev. Recorded Difference
No. reading V reading I seconds (t) energy-watt counted (N) energy-watt
seconds seconds

__________
174 Power: Wireman (NSQF Level - 4) Exercise 1.10.63
Power Exercise 1.10.64
Wireman - Measuring Instruments

Calibration of energy meters

Objectives: At the end of this exercise you shall be able to
• test and identify the creeping error
• test and starting current error of the energy meter
• test and calculate the percentage error in energy meter at resistive and inductive loads.

Requirements
Tools and Instruments • Lamp load single phase 240V 50 Hz
1.25 KW - 1 No.
• Wireman tool kit - 1 No.
• Auto-transformer 0-270V 10 Amp - 1 No.
• Single phase energy meter 5A
240 V 50Hz - 1 No. Materials
• Voltmeter 0 to 300 volt M.I. - 1 No.
• Electric bulb 5W 240V with holder - 1 No.
• Ammeter 0 to 5A M.I. - 1 No.
• PVC insulated cable 1.5 sq.mm
• Power factor meter 240V 5A 50 Hz - 1 No.
250V grade - 10 m.
• Ammeter M.I. 0-100 mA - 1 No.
• DPIC switch 16A 240V - 2 Nos.
Equipments/Machines
• Single phase capacitor motor with
brake load 240V 50 Hz AC 1/2 kW - 1 No.

PROCEDURE
Adjustment of error inside the energy meter is beyond the scope of this course as it requires costly
equipment like rotating sub-standard meter etc. Hence the simplified method of finding errors only is
included here.
TASK 1: Check the energy meter at no load to find the creeping error
1 Connect the energy meter through an auto transformer For an energy meter rating of 240V the input
as in Fig 1. voltage is between 192V to 264V. Observe, if
2 Vary the input voltage to the energy meter between the meter disc is rotating or not. The load should
80% and 110% of the rated voltage of the energy meter. not be connected or the load switch should be
'off' during the observation period.
3 Write your observations correlating your findings from
the above experiments with the recommendeation given
in I.S. 722.
Observation
As per I.S. 722 (Part I) the meter shall not make
a complete revolution at any voltage between
80% and 110% of the reference voltage.
If it moves and rotates slowly intend load, It
confirms that creeping error occurs in this
meters.

__________

TASK 2: Test for starting current error in energy meter

1 Connect low load (5 W lamp) as in Fig 2. 3 Write your observation correlating your finding from the
above experiment with the recommendation given in IS
2 Switch ON the load and observe the meter rotation.
722 (Part II and Part III).

175
 Observation
As per I.S. 722 (Part II) 1977 the starting current
shall be 0.5% of the rated basic current at cos 
= 1 for dial and pointer type register. Whereas
for drum type register it will 0.75%. For meters
provided with reverse stop the values will be
1% and 1.5% respectively.

__________
TASK 3: Test for percentage error in single phase energy meter
1 Make the connections as in Fig 3 with the lamp load.
n
2 Switch 'ON' the lamps so that 25% of the rated current  kWh
k
of energy meter flows in the circuit.
3 Tabulate the voltmeter, ammeter and P.F. meter readings 7 Find the error using the formula.
in Table 1. Error = Recorded energy (R) - True energy (A).
4 Keeping the load constant, count the number of 8 Calculate the percentage error, usig the formula.
revolutions of the energy meter disc for 2 minutes (120
seconds) and record the same in Table 1. R-A
Percentage error   100
5 Calculate the true energy by using the formula. A

E  I  Cos  t Where R = Energy registered by the meter

True Energy  kWh
1000  3600 A = True Energy
9 Repeat the working steps from 2 to 8 for 50% and 100%
where 't' is the time in seconds.
resistive and inductive load and enter in Table 1.
6 Calculate the energy registered (recorded) by the meter
For inductive load, make the connection as in Fig 4.
using the formula.

No. of revolution
Recorded Energy  kWh
Meter Constant

176 Power: Wireman (NSQF Level - 4) Exercise 1.10.64

 For checking the proper registration of energy, If the above errors are beyond the limitation
verify the readings through initial and final prescribed in I.S., take action for calibration
reading differences recorded in the energy of the energy meter, at the, meter and relay
meter. testing department attached to the electricity
board.
As per I.S. 722 (Part III) 1977, the percentage
error shall not exceed  2%, both at unity power
factor and at 0.5 lagging.
__________
TASK 3: Test for percentage error in single phase energy meter

1 From the tabulated readings, plot the graph of

percentage load versus percentage error separately for
unity PF and for lagging PF in Fig 5.
2 Show the error graph to your instructor and discuss
with him regarding meter calibration through the
electricity board.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.10.64 177

Power Exercise 1.10.65
Wireman - Measuring Instruments

Measurement of current and voltage using CT and PT, Measurement of 3 Phase

energy using CT and PT. Phase sequence meter, measure current and voltage
using Tong tester
Objectives: At the end of this exercise you shall be able to
• measure the current using CT
• measure the alternating voltage using PT
• measure 3 phase energy using CT & PT
• use of phase sequence meter
• measure current and voltage by using 100g tester.

Requirements
Tools and Instruments • Potential transformer 220/110V 10VA - 1 No.
• Auto-transformer 240V 50Hz, and
• Wireman tool kit - 1 No.
415V/110V 3 phase 0-270V, 10A - 1 No.
• M.I. voltmeter 0 - 300V - 1 No.
• Load - hot plate 2 KW 240V - 1 No.
• M.I. voltmeter 0 - 150V - 1 No.
• Heater 1.5 KW 240V - 1 No.
• M.I. ammeter 0 - 10A - 1 No.
• M.I. ammeter 0 - 5A - 1 No. Materials
• Multimeter/ohmmeter - 1 No.
• Single pole single throw (SPST)
• Megger 500V - 1 No.
switch 16A, 240V - 1 No.
• 3 Phase 2 element and 3 element
• Fused DP switch 240V 16A - 1 No.
energy meters (500V/5A) - 1 No each.
• PVC insulated copper cable 18/0.2
• Tong tester meter manual -
grade 250V - 10m
100/50/25/10/5A - 1 No.
• PVC insulated copper cable 23/0.2
Equipments/Machines grade 250V - 5m.
• 10 amps fuse wire - as reqd.
• Current transformer 10/5 amp 10VA
• 3 Phase motor 5/volts, 415V - 1 No.
and 25A/5A - 1 No. each.

PROCEDURE
TASK 1: Measurement of current using CT

1 Note down the name-plate details of the given CT in 2 Identify the pairs of primary and secondary terminals
Table 1. of the current transformer by the size of the terminals.
Table 1 Normally primary terminals will be larger in
size and secondary terminals will be smaller
Name - plate details of CT
in size.
1 Primary terminal markings _________
3 Ascertain the primary and secondary terminals of the
2 Secondary terminal markings _________ current transformer from the terminal markings and
verify your finding with that of step 2.
3 Rated frequency _________
4 Identify the polarity of the current transformer from the
4 Rated transformation ratio _________
alphabetical numberical order of marking.
5 Rated primary current _________A
5 Check the primary and secondary windings with the
6 Rated secondary current _________A help of an ohmmeter for short and open circuits.
7 Rated output _________VA Primary may have single or a few turns and in
8 Type _________ some cases the primary may have a single
cable passing through the circular would
9 Serial No _________ secondary. Secondary winding may have more
10 Manufacturer's name _____country _________ number of turns would with thin insulated wire.

11 Any other information ________ 6 Record the value of winding resistances in Table 2.

178
 Ascertain the type of primary winding and As a precaution, whenever you desire to
check accordingly. However by comparison the disconnect the ammeter from the secondary
primary winding will show low resistance of the CT, switch off the supply, remove the
value and the secondary winding will show ammeter and then short the secondary of the
slightly higher value of resistane. CT by a link and only then switch 'ON' the
supply.
Do not touch the terminals with bare hand.
While measuring, use insulated probes only 9 Connect the ammeter A2 to the secondary of the CT
as there may be shock hazards due to high and also connect one lead (S2) of the secondary of the
induction even though the supply is not CT with the earth connections.
connected.
10 Note the CT ratio, determine the multiplication factor
7 Connect the ammeter A1 to the primary of the CT and and enter the values in Table 3.
load (hot plate) as per circuit diagram Fig 1.
Example: If CT ratio is: 100:5

Primarycurrent 100
Multiplication factor    kWh
SecondaryConstant 5

11 Close the main and load (hotplate) switches.

Observe and record the reading of the ammeter in
Table 1.
12 Switch 'OFF' the supply and calculate the load current.
A3 = A2 x Multiplication factor (Transformation range)
8 Ascertain that the ammeter continuity is OK by 13 Take the readings for various heat range settings
pretesting. hotplate and enter them in Table 3.
Secondary of CT should never be open 14 Repeat the above steps, using an electric heater.
circuited, when the supply is 'on'. The
secondary winding of the CT should always be
either short circuited or connected to the
ammeter; otherwise dangerous voltage may
develop across CT secondary terminals.

Table 2
Sl. Description Resistance Condition (Strike off Remarks
No. value in ohms which is not applicable)

1 Primary winding Short/Open/OK

2 Secondary winding Short/Open/OK

Table 3
Sl. Load CT Multiplication Secondary Calculated Measured
No. particulars ratio factor load load load
(M.F.) (A2) in amps current current
A3=A2 x MF (A1) in amps

1 2 kW 230V Hotplate

2 Range 1

3 Range 2

4 Range 3

5 Electric heater
1.5 kW x 240V

__________

Power: Wireman (NSQF Level - 4) Exercise 1.10.65 179

TASK 2: Measurement of current using PT 7 Check the insulation resistance of the primary and
1 Note down the name-plate details of the given PT in secondary winding for short between windings and
Table 4. ground with the help of a megger.

Table 4 8 Record the values in the Table 7.

If you find leakage or short, inform your
Name - plate details of CT
instructor and get a replacement.
1 Primary terminal markings _________
9 Make the connections as per circuit diagram Fig 2.
2 Secondary terminal markings _________ (Load may or may not be connected).
3 Rated frequency _________
4 Rated transformation ratio _________
5 Rated primary current _________A
6 Rated secondary current _________A
7 Rated output _________VA
8 Type _________
9 Serial No _________
10 Manufacturer's name _____country _________ 10 In the case of earthed type PT, connect one lead of
secondary of PT with earth connections.
11 Any other information ________
11 Note the PT ratio and determine the multiplication factor.
2 Identify the pairs of the primary and secondary terminals 12 Close the main switch and set the input voltage to the
of the potential transformer by the size of the winding rated value of the supply.
wires which are connected to the terminal.
13 Observe the voltmeters (V1 & V2) reading and record
Normally the primary winding will be having Table 5.
thicker insulation and the secondary winding
will be having thinner insulation. 14 Repeat the above steps for different (atleast size) to
input voltages and record the values in Table 6.
3 Ascertain the primary and secondary terminals of a
potential transformer from the terminal marking and 15 Switch 'OFF' the supply. Calculate the input supply
verify your finding with that of step 2. voltage.

4 Identify the polarity of the potential transformer from V3 = V2 x Multiplication Factor

the alphanumeric order of marking. 16 Calculate the errors percentage.
5 Check the primary and secondary winding with the help 17 Write your observations
of an ohmmeter for short and open circuit.
___________________________________________
Primary may have large number of turns
wound with a thin wire whereas the secondary 18 Show the readings to your instructor for approval.
may have a few turns of the same wire. Example: PT Ratio 220: 110 or 2:1
However, by comparison the primary winding
will show high resistance value and the Primarycurrent 100
secondary will show low resistance value. Multiplication factor   kWh
SecondaryConstant 5
Do not touch the terminals while measuring.
Use insulated probes as there may be shock
hazards due to high induction.
6 Record the value of winding resistance in Table 6.
If found short or open immediately report to
your instructor and get the replacement.

Table 5
Sl. Description Resistance Condition (Strike off Remarks
No. value in ohms which is not applicable)

1 Primary winding Short/Open/OK

2 Secondary winding Short/Open/OK

180 Power: Wireman (NSQF Level - 4) Exercise 1.10.65

 Table 6
Sl. PT Multiplication Secondary Calculated Measured
No. ratio factor voltage primary primary
(M.F.) (V2) voltage voltage
V3=V2 x MF (V1)

__________

TASK 3: Measurement of energy in 3-phase system using CTs and PTs

1 Connect CTs, PTs, energy meter and load as in Fig 3 2 Keep the load switches open and then switch 'ON' the
and 4 according to the availability of the energy meter. power supply.
3 Switch 'ON' the load and adjust the load such that each
of the ammeters reads 10 amps approximately.
For a balanced load all the three ammeters
should read equally. If the ammeter readings
are different, the load is unbalanced.
4 Note down the initial reading of the energy meter and
the time in Table 7.
5 Keep the load constant for 1 hour. Note down the final
reading of the energy meter, time and record in
Table 1.
6 Calculate the energy recorded = Final reading - Initial
reading
7 Caculate the actual energy using the formula.
Actual energy = Recorded energy x CT ratio x PT ratio
8 Repeat the steps from 3 to 7 for different loads and
meter the readings in Table 7.
9 Switch OFF the supply and disconnect the meters.
10 Get it checked by your instructor.
Write the Conclusion:
Energy in a 3-phase circuit could be measured using CT
and PT.
Remove the shorting link between current and The actual energy consumed = Energy meter reading in
voltage terminals of the energy meter. kWh.

Power: Wireman (NSQF Level - 4) Exercise 1.10.65 181

 Table 7

Sl. Load C.T. PT Initial Final Total actual energy Time

No. Ratio Ratio reading reading consumption = (FR-IR) Initial - Final
of energy of energy x CR ratio x PT ratio
meter (IR) meter (FR)

__________

TASK 4: Use of phase sequence meter - already explaned in Ex.No. 1.2

__________

TASK 5: Measure the current by using a tong-tester or clip-on ammeter

1 Set the range selector switch at the highest range of
the meter. (Fig 5)

Read the instruction booklet given along the

tong-tester and follow the manufacturer's
directions.
2 Open the CT core loop of the clip-on trigger by
squeezing the spring lever.
3 Insert the insulated cable carrying current (lighted load)
in the loop (of the tong-tester) and release the lever.
(Fig 6)
Look for perfect seating of the core of the CT
loop.
4 Read the meter. Is the deflection within the first one-
fifth (1/5th) of the scale in a higher range? If 'NO' go to
step No.7.
5 If YES, change the range setting to the next lower
range.
6 Repeat the above steps until the deflection is 20% of The actual current is obtained by dividing the
the appropriate range. indicated value by 2.
If the reading is less than 20% of FSD of the 7 Record the readings in Table 8.
lowest range scale make one turn of cable
8 Remove the meter by opening the CT core loop.
around the CT loop. (Fig 7)

182 Power: Wireman (NSQF Level - 4) Exercise 1.10.65

9 Measure the current of the primary of the AC welding Table 8
transformer at different setting of transformer secondary,
No. Reading Range Current Name of
phase current of the 3-phase induction motor on load
load/device
(pump, lathe or any other drive).
10 Enter the readings in Table 8.

__________
TASK 6: Measure the voltage using tong tester

1 Set the function switch to AC voltage position. 5 Set the function switch to DC voltage postion and repeat
the steps 1 to 4 to measure the DC voltage.
2 Plug the black test leed to in common jack, and red
test lead in positive jack. D.C. voltage is ............ volts.
3 Connect the AC supply to the leads which voltage is to Phase sequence meter was already dealt in previous
be measured. exercise No. 54
4 Take the reading shown in tang tester dial and record.
A.C. voltage is ................. volts.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.10.65 183

Power Exercise 1.10.66
Wireman - Measuring Instruments

Power measurement by Two and Three watt meter method Insulation resistance
test by Megger
Objectives: At the end of this exercise you shall be able to
• connect two wattmeters in the circuit as per the given diagram
• measure the power by two wattmeter method and calculate the power factor
• measure line 3d power by two wattmeter method
• measure the 3 phase power by using 3 wattmeter method.

Requirements
Tools and Instruments Equipments/Machines
• Screw driver 150 mm - 1 No. • 3 phase, 415V AC induction motor 5 HP - 1 No.
• Wattmeter 500V/5A, 3 KW - 3 Nos.
Materials
• M.I. Voltmeter 0-500V - 1 No each.
• M.I. Ammeter 0-5A - 1 No. • 200W, 250V lamps - 3 Nos.
• Megger 500V - 1 No. • 100W, 250 lamps - 3 Nos.
• Cutting plier 150 mm - 1 No. • Connecting leads - as reqd.
• Pendent-holders 6A 250V - 6 Nos.
• Armanred cables different size
and lengthen - as reqd.

PROCEDURE
TASK 1: Measure the power in 3 phase circuit using two wattmeter and calculate power factor

1 Form the circuit as per the given circuit diagram. 4 Read wattmeters W1 & W2 and record in Table 1. Add
(Fig 1) the readings W1 and W2 and record the total power; go
to step 6.
Connect proper ranges of meters suitable for
the given load. 5 Switch on the supply and read the wattmeters W1 &
W2. Record the values in the Tables. Record the
readings of the wattmeter with the changed potential
coil as negative quantity.
6 Measure the 3-phase power for different load conditions
specified below:
a L1 = 300 W bulb
L2 = 300 W bulb
L3 = 300 W bulb
b L1, L2, L3 water load to take a current of max.3
2 Switch 'ON' the 3-phase supply and observe for the amps.
proper deflection of wattmeters. If both wattmeters
deflect properly, go to step 4, otherwise continue from c Induction motor 3 HP on no load.
step 3. d Induction motor 3-HP with load.
3 Switch 'OFF' the supply, if any one wattmeter deflects The instructor personally to connect the three-
in the reverse direction. Change the connection of the phase motor for proper running.
potential coil of the reverse deflection wattmeter. Go to
step 5. 7 Calculate the power factor in all the above cases and
enter them in Table 1.
8 Get your work checked by Instructor.

184
 Table 1

Calculated Power factor Cos
Types of Wattmeter W1 Wattmeter W2 Total
Load W1 + W2
 W1  W2  
Cos
Tan   3
 W1  W2 

1
2
3
4
5

Conclusion: __________________________________

__________
TASK 2: Measure the 3 phase power by 3 wattmeter method

1 Select the proper range of wattmeter. 5 Record the readings in the Table 3.
2 Form the circuit as per circuit as in Fig 2. 6 Repeat the steps 2 to 6 for two more loads and record
in Table 3.
7 Connect two bulbs in each phase in parallel for ammeter
load.
8 Get the approval from the instructor after completing
the task.
Table 3

Sl. Volt Measurement W1 W2 W3 WT=W1

No. V Ammeter Meter

2
3 Switch ON the 3 phase supply by changing the position
of switch 'S'.
3
4 Note down the readings of voltmeter, Ammeter, and
three wattmeters.
__________
TASK 3: Test the megger for proper function

1 Note dwon the name-plate details of the megger in 3 Short the two terminals Earth (E) and Line (L) and,
Table 4. rotate the handle and confirm that the pointer reads
'ZERO'
Table 4
In case the infinity and zero readings could
Type .........................
not be obtained, inform your instructor.
Range ...........................
4 Connect the two terminals 'E' & 'L' with the 0 - 600 V.
Voltage ..........................(V) Speed...........Rev./Min MC voltmeter as in Fig 3.
Sl.No. ................................ 5 Rotate the handle at the rated speed steadily and
observe the reading of the voltmeter.
Manufacturer ..........................
Result
Country .................................
Voltmeter reading .................. volts
2 Keeping the two terminals Earth (E) and Line (L) open,
rotate the handle at about 160 rpm (or at its related The voltmeter should read the rated voltage
speed) and observe that the pointer reads 'INFINITY' which is inscribed on the name-plate of the
(). insulation tester.
Power: Wireman (NSQF Level - 4) Exercise 1.10.66 185
 __________
TASK 4: Measure insulation resistance between conductors of an armoured cable

1 Connect the armoured cabe as in Fig 4. Rotate the insulation tester handle steadly at
Connect the guard terminal of the meter with constant speed atleast for one minute duration
the armour (metal sheath) of the cable. before recording the meter reading.

2 Measure the insulation resistance between the

conductors and record the readings in Table 5.
Table 5
Measurement Insulation
resistance
in megohms
Between conductors
Conductor 1 & conductor 2
Conductor 2 & conductor 3
Conductor 1 & conductor 3
Between earth and conductors
Conductor 1 & earth
Conductor 2 & earth
Conductor 3 & earth
Conductor 1,2,3 shorted & earth

__________
TASK 5: Measure insulation resistance between earth and conductors of an armoured cable
1 Connect the armoured cable as in Fig 5. Discuss with your instructor regarding the
If the armoured cable is burled in the ground required insulation resistance value of the
connect the megger as in Fig 5. If the cable is cable.
not burled but kept on ground surface or on The instructor is advised to demonstrate the
the working table, the earth connection should use of transistorised megger for various tests.
be made as shown in Fig 6.
Table 6 missing
2 Measure the insulation resistance between earth and
each conductor and record the readings in Table 6. Table 2 missing

3 Measure the insulation resistance between earth and

all three conductors by shorting together and record
the reading in Table 6.

186 Power: Wireman (NSQF Level - 4) Exercise 1.10.66

 __________

Power: Wireman (NSQF Level - 4) Exercise 1.10.66 187

Power Exercise 1.10.67
Wireman - Measuring Instruments

Measurement of earth resistance by earth tester

Objectives: At the end of this exercise you shall be able to
• measure known resistance using three/four terminal earth tester
• measure earth resistance using three/four terminal earth tester.

Requirements
Tools and Instruments/equipment Equipment/Materials
• Earth testing 3&4 terminals each - 1 No. • Resistors: wire-wound or carbon 2.5
• Metal spikes - 2 Nos. 8.2, 10, 12, 100 and 470 ohms
• Standard cable (preferably the one of any wattage (Each) - 1 No.
supplied along with the earth tester) - 3 Set. • Plate earthing - 1 No.
• Pipe wrench 250mm long - 1 No.
• Screwdriver 200mm - 1 No.
• Straight pein hammer 1.5 Kg - 1 No.
• Spanner set 5 mm to 20 mm - 1 No.

PROCEDURE
TASK 1: To check the accuracy of earth resistance tester with known resistors
1 Collect the earth tester
2 Note down the name-plate details in Table 1.

Table 1
Type 3 Terminals / 4 Terminals
Range Single/Multi
Serial No ------------------------------
Accuracy ------------------------------
Rotation speed ------------------------------
Manufacturere ------------------------------
Country ------------------------------

Read and interpret the instruction manual

supplied with the earth tester for proper
measurement or earth electrode resistance.
The following are the general guidelines for
the use of the earth tester in common use.
3 Connect the known resistor 'R' as per circuit diagram
in Fig 1.
In the case of a four terminal tester make
connections as per circuit diagram - Fig 2.
4 Rotate the generator handle to the required speed unitl
the pointer comes to rest.
5 Observe the reading of the instrument in ohms and
record in Table 2.
Take care of the range factor in the case of a
multi-range earth tester.
6 Measure atleast four known resistors by following steps
No. 3 to 5. Record the values in Table 2.
188
 This measurement exercise is done to check Table 2
the measurement accuracy of the earth tester. S.No Readings in ohms
In case of wide variation between the
indicated value and the measured value, Indicated value Measured value
discuss with the instructor. 1
7 Show your readings to your instructor for approval. 2
3
4

__________
TASK 2: To check the accuracy of earth resistance tester with known resistors
1 Drive the metal spikes at a distance of 15 m each from
the earth electrode in a straight lines as in Fig 3.

However refer to the instruction manual

supplied with the earth tester abd follow the
instructions regarding the distance between
the spikes and the earth electrode as well as
the pattern i.e. straight or equilateral triangle.
2 Connect three terminals of earth tester with the earth
plate under test and metal spikes as in Fig 3. 6 Select the highest reading out of the set of readings as
In the case of a four terminal tester make the the actual value of the earth electrode resistance.
connection as per circuit diagram (Fig 4). 7 Show the readings to your instructor and discuss with
Use only the accessories (like spike and cables) him the most (suitable protection for the circuit based
supplied along with the earth tester by the on the earth electrode resistance.
manufacturer. Table 3
S.No Location Earth Actual value
3 Rotate the generator handle at the rated speed until
electrode electrode
the pointer comes to rest.
resistance resistance
4 Read the earth electrode resistance from the meter in ohms (Highest value
and enter the same in Table 3. out of the four
5 Take three more readings by shifting the position of readings)
the spikes by 90º around the earth electrode under 1
test as in Fig 5.
2
If the electrode is near a wall of a building
3
atleast 3 readings could be taken by shifting
the spikes at 45º. 4
__________
Power: Wireman (NSQF Level - 4) Exercise 1.10.67 189
Power Exercise 1.10.68
Wireman - Measuring Instruments

Calibration of indicating type analogue instruments: voltmeter, ammeter, and

wattmeter. Measurement of soil conductivity. Introduction of Digital meters
Objectives: At the end of this exercise you shall be able to
• calibrate the repaired ammeter using calibrator
• calibrate the repaired voltmeter using standard meter
• calibrate wattmeter using voltmeter and ammeter
• calibrate wattmeter using standard wattmeter
• measure the dial connectivity
• read and interpret the digital method.

Requirements
Tools and Instruments/equipment • Line tester - 1 No.
• Instrument/watch maker screw
• MI Ammeter 0 to 100mA - 2 Nos.
drivers - 1 Set.
• MI Voltmeter 0 to 10V - 2 Nos.
• Digital soil conducting tester 200 - 1 No.
• Wattmeter 250V/5A-Dynamometer
type - 8 Nos. Materials
• Standard meter/Voltmeter,
• Connecting leads - as reqd.
Ammeter - 1 No each.
• Insulation tape roll - 1 No.
• DC power source 0 to 10 volt, 1 amp - 9 Nos.
• Bulbs 250V AC assorter power range - as reqd.
• Potentiometer wire wound type,
• Load base (i.e. 12" x 8" board fitted
1kohm, 5W - 1 No.
with pattern holders - 1 No.
• Screw driver 6" long - 1 No.
• Electrode kit - 1 No.
• Nose plier 4" dia - 1 No.
• Cutting plier 150 mm - 1 No.

PROCEDURE
TASK 1: Calibration of Ammeter
1 Check the specifications of the master meter or
calibrator.
2 Ensure whether repaired meter (MC/MI type) would
match the specifications of the calibrator and connect
as in Fig 1.
(OR)
3 Connect the meter as per diagram with master meter
and ensure polarities are conneced properly as per
Fig 1.
4 Keep the Rheostat or Variable resistor in the maximum
position and apply variable DC voltage in steps and
observe the readings in both the meters and note down
in Table 1.
5 Note down the readings and find out the error of the
instrument under test.
6 Observe the errors for various inputs and if the % of
error is too much, carry out necessary sevicing of the
instrument and redo the calibration procedures.

190
 Table 1
Sl.No. Standard meter readings Under test meter reading % Error
1
2
3
4
__________
TASK 2: Calibration of Voltmeter (MC)

1 Select suitable range standard voltmeter instead of

ammeter.
2 Connect the standard voltmenter in parallel with the
instrument under test with multiplier resistance included
in the instrument as in Fig 2.
3 Take the readings in small steps of voltage and find out
the error of the instrument in Table 2.
If the errir is too much, necessary repairs and
servicing should be carried out and should be
recalibrated once again.

Table 2
Sl.No. Master meter readings Under test meter reading % Error
1

4
__________
TASK 3: Calibration of Wattmeter using Voltmeter and Ammeter
1 Connect the instruments Wattmeter, Voltmeter and
Ammeter as in Fig 3.
2 Connect the bulb loads as in Fig 3.
3 Provide fuse 5Amps at both the input terminals i.e.
Phase and Neutral as in Fig 3.
4 Switch 'ON' the supply and switch 'ON' the loads.
5 Take reading by changing different load in voltmeter,
ammeter and wattmeter and record it in Table 3.

Table 3
Sl.No. Voltmeter reading Ammeter reading Power calculated Wattmeter reading Error
VxI
1

4
__________
Power: Wireman (NSQF Level - 4) Exercise 1.10.68 191
TASK 4: Set and operate the soil conductivity tester for measurement

1 Arrange the spikes on the gound where the soil 9 Connect all the electrodes P1 P2 C2 and repeat the step
conductivity is to be tested in a straight line as in the 4,5 and 6.
Fig 4 in equal distance between spikes. Preferably 3
10 Remove the electrode P1, P2 & C2 and fit in at 90º
meter in distance. The spikes should be buried in the
direction to C1 electrode.
ground minimum ¾ of its full length.
11 Repeat the steps 4,5 and 6.
The depth of spikes in the ground should be
equal and uniform in the equal distance. (say 12 Compute all the values and find the soil conductivity
3 metre distance). ohm/metre. Record it in the Table 4.
2 Connect the electrodes to the soil conductivity tester You must have at least 3 sets of readings in
in the respective sockets in the order of C1 P1 P2 & C2. different direction and the value can be taken
on the mean value of the 3 readings.
Do not interchange the spikes order C1 P1 P2 &
C2 it may give wrong reading.
3 Cheek the connection to the electrodes for its tightness.
It should be tight.
4 Set the knob to the lowest ohms range in the meter.
5 Operate the instrument by pressing the 'ON' switch
and read the value.
6 Increase the ohms range to the next position if the
meter shows infinity.
7 Note down the values shown by the meter in Table 4.
8 Remove the electrode P1, P2 & C2 and fit in the opposite
side while keeping C1 in the same place.

Table 4
Sl.No. Reading shown by meter Value calculates = 2  ER  /mtr

1
2
3
4
5
__________
TASK 5: Interpret the digital instruments

Instructor has to arrange and provide digital 1 Take any one the digital meter from table and write its
meters available in the section on the Table. name, type and its features in Table 1.
Explain about digital meters features and 2 Take other meters and write their names, type and their
compare merit and dermits between analog details in Table 2.
and digital meters.
3 Get it checked by your instructor.

Sl.No. Instruments Name of the meter Type and features

192 Power: Wireman (NSQF Level - 4) Exercise 1.10.68

Sl.No. Instruments Name of the meter Type and features

__________
Power: Wireman (NSQF Level - 4) Exercise 1.10.68 193
Power Exercise 1.11.69
Wireman - Domestic Wiring Practice - I

Demonstration and Practice on connecting common electrical accessories in

circuits and testing them in series board
Objectives: At the end of this exercise you shall be able to
• prepare the cable end for loop termination on screw terminal
• connect 2 pin plug and socket complaint
• connect appliance plug socket to cable with earth contact
• connect 3-pole power plug pin connect the cable
• make under writers knot for connecting and pendent holder with cutting rose.

Requirements
Tools and Instruments Materials
• Steel rule 300 mm - 1 No. • PVC cable 3-core copper 23/0.2 mm - 5 m.
• Electrician's knife 100 mm - 1 No. • Socket 2-pole with earthing contact
• Wire stripper (manual) 150 mm - 1 No. 6A, 250 V grade - each of different
• Combination pliers 200 mm - 1 No. rating and make - 4 Pairs.
• Screwdriver 100/50 mm x 4 mm - 1 No. • Plug 2-pole with earthing contact - 4 Pairs.
• Screwdriver 100mm x 2 mm - 1 No. • Soldering lead resin core 60:40 grade - 10 gms.
• Long round nose pliers 150 mm - 1 No. • Soldering paste - as reqd.
• Test lamp with bulb 40 W, 240 V - 1 No • Socket 2-pole with earthing contact 6A - 5 Nos.
• Soldering iron 65 W, 240 V - 1 No. • PVC cable 3-core 48/0.2 mm - 3.5 m.
• Side cutting pliers 150 mm - 1 No. • Plug 3-pole 6A, 250 V different makes - 2 Nos.
• Plug 3-pole 16 A, 250 V different makes - 2 Nos.
• Metal/cold plug 2-pin with earth 20A - 2 Nos.
• Appliance connector socket 20A - 1 No.

PROCEDURE
TASK 1: Connecting 2 pin plug and socket coupling
1 Remove the 'connection cover' of the socket coupling. 5 Draw the cable end for connecting to the screw terminals
through the cable clamp and tighten the cable clamp.
6 Adapt the length of the ends of the leads at the
connecting point. Twist and bend into loops, solder and
screw on. (Fig 1)
7 Refit the 'connection covers'.
8 Remove the 'connection cover' of the coupling plug.
9 Adopt the same steps Nos. 2 to 7 for the coupling
plug.
10 Repeat connecting up plug and socket coupling for
different current - carrying capacity/manufacture.
2 Loosen the cable clamp at the socket. 11 Check the connection for its continuity of L, N and E
with the test lamp. (Fig 2)
3 Strip the cable ends to the required length using the
stripper/knife.
Do not nick on the conductor while using knife
or stripper.
4 Prepare the ends suitably with the help of a nose plier
suitable to the shock-proof socket.
Cut excess length of cable inside the socket.
Bare wire - should be exact type and size of
the fixing screw.
__________
194
TASK 2: Connecting up appliance socket (Fig 3).

Do not nick on the conductor while using knife

or stripper.
4 Prepare the ends suitably with the help of a nose pliers,
suitable to the stock-proof socket.
5 Introduce the ends of the conductor leads through both
the sockets anti-kink sheathing (6) cable clamp (5).
6 Draw the cable end and tighten the cable clamp.
(Fig 3)
7 Adopt the length of the ends of the leads at the
connection point. Twist and bend into loops (4), solder
and screw on.
Use the correct size of screw driver for fixing
the screw.
1 Remove the connection cover (3) of the appliance 8 Refit the 'connection cover', check the connections for
socket. the continuity of L, N and E with a test lamp as in
2 Loosen the cable clamp (5) at the socket. Fig 2.

3 Strip the cable (1) ends to the required length with a 9 Repeat atleast four times connecting up the appliance
stripper or knife. sockets of different current carrying capacities/
manufacture.
__________
TASK 3: Connecting up 3-pole power plug

1 Remove the cover of the 3-pole plug.

2 Loosen the cable clamp.
3 Strip the cable at one end to the required length with
the stripper or knife.
Do not nick on the conductor while using
stripper or knife.
4 Prepare the ends suitably with the help of a noseplier
suitable to the plug.
No excess length of cable inside plug left
should be
Bare wire.
Exact type and size of fixing screw.
5 Insert conductor ends into the plug through the anti-
knit sheathing retainer cap (2), anti-kink sheathing (1).
(Fig 4)
6 Draw the cable end through the metal housing (3).
7 Adapt length of ends of lead at the connecting points,
twist, solder and screw.
Use the correct size of screwdriver for fixing
the screws.
8 Refit the connection cover, check the connections for
continuity with a test lamp as in Fig 5.
9 Repeat atleast four times connecting up the plug for
different current-carrying capacity/manufacture. (Fig 6)

Power: Wireman (NSQF Level - 4) Exercise 1.11.69 195

 __________

TASK 4: Make under writers knot for connecting and pendent holder with cutting rose.
1 Insert the flexible cord in the cover of the ceiling rose
and pendent-holder as in Fig 7.

2 Untwist the flexible cord as in Fig 8, to about 10 cms.

6 Pull both the wires finally to form a knot as in Fig 12.

3 Bend one-wire around a straight wire in the form of a

loop as in Fig 9.

7 Remove the insulation at the end of the cables and

connect them to the terminal screws of the lamp-holder/
ceiling rose.
8 Fix the cover over the base.
4 Bend the straight wire around the looped wire as in
9 Test the knot for its proper holding by gently pulling the
Fig 10.
flexible cords.
5 Insert the end of the wire in the first wire loop as in 10 Test the connected ceiling rose with pendent holder by
Fig 11.
_ _ _ _ _ _ _ _ using
_ _ series fert board.
196 Power: Wireman (NSQF Level - 4) Exercise 1.11.69
Power Exercise 1.11.70
Wireman - Domestic Wiring Practice - I

Demonstration on Testing and replacement of different types of fuses

Objectives: At the end of this exercise you shall be able to
• identify the different types of fuses
• test the different types of fuses by continuity
• replace the faulty fuses.

Requirements
Tools and Instruments/equipment Materials
• Fuse puller HN type - 1 No. • Flow next 63A HN tyoe fuse - 1 No.
• Nose plier flat 200 mm - 1 No. • Flown out 16A HRC fuse - 1 No.
• Digital multimeter - 1 No. • 63A HN type fuse new - 1 No.
• 16A HRC fuse new - 1 No.
• Kit-kat fuse 16A - 1 No.
• Class fuse (0.5, 1.5, 10A) - 1 No each.
• Bottle type DZ fuse 16A - 1 No

PROCEDURE
TASK 1: Identify and name the type of fuses given

Instructor may arc ways different types of fuses 1 Identify the type of fuses.
in the testing and explain how to identify the 2 Write the type of the fuse and their uses in Table 1.
types of fuses.

Table 1
Sl. Fuses Name of the fuse Type of fuse
No.
1

197
 Sl. Fuses Name of the fuse Type of fuse
No.

3 Get it approved by the instructor.

__________

TASK 2: Testing the diferent type of fuse

1 Take the digital multimeter or ohm meter set the correct
range for continuity test. (Fig 6)
2 Connect fuse ends and read/view the meter's values.
If the continuity not OK, replace the fuse.
3 Replace the faulty fuse.

__________

TASK 3: Replace of different type of fuse

1 Replace the fuse as it is same specification in correct While replace the use suitable/correct tools
rating. only and follow
Safety preacutions.
__________

198 Power: Wireman (NSQF Level - 4) Exercise 1.11.70

Power Exercise 1.11.71
Wireman - Domestic Wiring Practice - I

Identification of different wiring materials and their specifications

Objectives: At the end of this exercise you shall be able to
• identify different wiring materials and their specification
• write are use of each materials.

Requirements
Materials • Brass angle batten holder - 1 No.
• Wooden angle batten holder - 1 No.
• PVC casing and capping 25mmx10mm - 2 mtr.
• Wooden box 100 x 100 x 50mm - 1 No.
• PVC conduit pipe 19mm - 3 mtr.
• Wooden box 150 x 100 x 50 mm - 1 No.
• Metal conduit pipe 19mm - 3 mtr.
• Wooden box 200 x 150 x 50 mm - 1 No.
• PVC round block 90mm x 40 mm - 1 No.
• Wooden box 300 x 200 x 50 mm - 1 No.
• PVC/Metal junction boxes 19mm
• Wooden box 300 x 250 x 50 mm - 1 No.
1 way, 2 way, 3 way and four way - 1 No.
• 16Amps/3 way terminal plate - 1 No.
• PVC bend 19mm - 1 No.
• 23/240V 6 way distribution fuse box - 1 No.
• PVC 'L' bow 19mm - 1 No.
• 12 way neutral link - 1 No.
• Saddle (P.V.C) 19mm - 1 No.
• Solid metal conduct bend - 1 No.
• Steel nail 25mm - 1 No.
• Inspection metal conduct bend - 1 No.
• Wooden screws assorted sizes - as reqd.
• Terminal connector - 1 No.
• 1.5 mm2 multi strand copper PVC/cable - 5 mtr.
• PVC 19mm 'T' - 1 No.
• 1.5 mm2 Aluminium PVC cable - 5 mtr.
• Metal conduct 'T' 19 mm - 1 No.
• 6A/240V Flush type one way switch - 1 No.
• Inspection metal conduct 'T' 19 mm - 1 No.
• 6A/240V Flush type two way switch - 1 No.
• Metal conduct coupling 19 mm - 1 No.
• 16A/240V Flush type one way switch - 1 No.
• Inspection metal conduct elbow 19 mm - 1 No
• 16A/240V 3 pin socket - 1 No.
• IC main switch 240V/16A/32A ICDP - 1 No.
• 6A/240V 3 pin socket - 1 No.
• 6A/240V, 2 plate ceiling rose - 1 No.
• Bakelite straight batten holder 250V/6A - 1 No.

PROCEDURE
TASK 1:
1 Identify each items and write the name in the Table 1.
Instructor shall display the above wiring
materials and demonstrate how to identify and 2 Write the specification and use of each conduit and
their application of each material with its name conduit accessory in the column given wiring materials
and specification. in Table 1.
3 Show to your instructor and get approval.

199
 Table 1
Sl. Sketch of the material Name Specification Uses
No.

200 Power: Wireman (NSQF Level - 4) Exercise 1.11.71

Sl. Sketch of the material Name Specification Uses
No.

Power: Wireman (NSQF Level - 4) Exercise 1.11.71 201

Sl. Sketch of the material Name Specification Uses
No.

202 Power: Wireman (NSQF Level - 4) Exercise 1.11.71

Power Exercise 1.11.72
Wireman - Domestic Wiring Practice - I

Removing of insulation from assorted wires and cables

Objectives: At the end of this exercise you shall be able to
• skin the cable insulation using the electrician's knife
• skin the cable insulation using manual stripper
• skin the cable insulation using auto-stripper
• practice on making a straight twist joint
• prepare termination of cable lugs using crimping tool.

Requirements
Tools and Instruments/equipment Materials
• Electrician tool kit - 1 No. Aluminium cables of the following sizes:
• Electrician's knife 100 mm blade - 1 No. • PVC single strand cable
• Wire stripper, manual 200 mm - 1 No. 1/1.4, 1.5 sq. mm -3m
• Wire stripper auto–eject 150 mm - 1 No. • PVC single strand aluminium cable
• Combination pliers 150 or 200 mm - 1 No. 1/1.8, 2.5sq. mm -3m
• Steel rule 300 mm - 1 No. Flexible cables with copper conductor of size:
• Diagonal cutter or side cutting pliers • PVC cable 14/0.2 mm -3m
150 mm - 1 No. • PVC cable 23/0.2 mm -3m
• PVC cable 48/0.2 mm -3m
• PVC cable 80/0.2 mm -3m
• PVC cable 128/0.2 mm -3m
• PVC cable,PVC sheathed cable
– assorted small pieces -as reqd

PROCEDURE
TASK 1: Skinning cable insulation using the electrician's knife
1 Mark the length of the 1.5 sq. mm cable at 400 mm
from its end.
2 Cut the cable using combination pliers on the mark.
3 Mark the length of insulation to be skinned from either
end. (Fig 1)
7 Clean the surface of the bare conductor and show it to
the instructor.
8 Cut the cable at 12 mm from either end using a
combination plier.
9 Repeat steps No.5 to No.8, until the cable is of 350
mm length
4 Check the sharpness of the knife blade and re-sharpen,
if necessary. 10 Mark the insulation that is to be removed as in Fig 3
and repeat steps 5 and 6.
Use an oilstone to sharpen the knife's blade.
Visible thickness at the cutting edge of the
knife blade indicates a blunt edge. In the case
of a sharp edge, the thickness or end will not
be visible.
5 Remove the insulation of the cable for about 10 mm at 11 Repeat the skinning of cable insulation of 2.5 sq. mm,
the ends using a knife. (Fig 2) Keep the knife blade at 14/0.2 mm, 23/0.2 mm, 48/0.2 mm, 80/0.2 mm and
an angle less than 20° to the cable. 128/0.2 mm flexible cables.
6 Check for nicking over the conductor. Also check if the The length of the cable after skinning both the
cable is not shaved. ends shall be suitable for termination using
crimping and screw.

203
12 The length of the finished skinned cable should be 300, In the case of flexible stranded cables to
500, 600, 800, 1000 mm. ensure that the strands are not cut is essental.
These cable pieces are to be used for later
exercises.
__________
TASK 2: Skinning cable insulation using a manual stripper
1 Mark the length of the cable to be trimmed off. Partially cut insulation can be removed only
2 Trim the cable at the mark using a combination plier with more force. Excessive force, indicates
diagonal cutter. improper cutting of insulation.
3 Straighten the ends where the insulation is to be 8 Repeat the skinning of insulation for 10 mm to develop
skinned. skill in the use of the wire stripper.
4 Mark the point where the insulation is to be skinned. 9 Remove insulation to the required extent at the ends
as per Fig 4.
5 Adjust the jaws of the manual stripper and set them to
suit the cable conductor.
6 Set the jaws at the mark, press the handle of the
stripper and turn to cut the insulation.
Do not nick the conductor. For better practice Be caeful with flexible cables to ensure that
try on a small waste piece. you do not nick even a single strand.
7 Pull the stripper to remove the insulation.
__________

TASK3: Skinning cable insulations using auto-stripper

1 Mark the length of the insulation to be removed from 5 Press the stripper.
the ends.
Further pressing may damage the insulation
2 Straighten the cable ends. from the cable end, that is also to be removed.
3 Select a proper set of stripper. 6 Check that the cable conductor is not nicked.
4 Locate the jaws of the stripper exactly on the mark. 7 Repeat steps No 1 to 7 for different sizes of cables.

__________

Skill sequence

Hand tools for skinning - knife

Objectives: This shall help you to
• identify the parts of the knife used for skinning
• perform care and maintenance in using the knife.

The most frequently used tool for skinning is the knife. • back of the blade
A knife may have a single or double blade. A single blade • hanger
knife is the most commonly used one. (Fig 1)
• haft
• hinge pin
• blade
Becareful while using the knife.
Always cut keeping the object to be cut away from your
body.
Slice the insulation at an angle of approximately 15° to
avoid cutting into the conductor. (Fig 2)

204 Power: Wireman (NSQF Level - 4) Exercise 1.11.72

 Knives should not be used to remove insulation
on very fine single or stranded conductors.
Knives should not be used to cut conductors.

__________

Hand tools for skinning - manual wire stripper

Objectives: This shall help you to
• identify the parts of the manual wire stripper
• perform care and maintenance of manual wire stripper.

Hand operated wire stripping tools can be used to remove Often one cutter becomes sharper than the other, and
P.V.C. or rubber insulation from a single core cable without cuts more than halfway through the wires, damaging the
damaging the conductor. They are of two types manual conductors. In such an event, the blunt cutter should be
and auto-eject. sharpened.
Manual wire stripper: The jaws have V shaped notches Fig 3 shows manual wire stripper.
to cut the insulation.
The adjuster screw allows to cut a wide range of wire
diameters. (Figs 1 and 2).

This tool has a series of sharp openings in its scissor

blade to allow stripping of wire in gauge of different sizes
or diameters. The gauge size of the wire must match with
the opening in the wire stripper to prevent cutting into the
wire and weakening it.
Precautions:
• When using this tool, make sure that it is
correctly adjusted before trying to strip the
insulation from the cable so that it does not
damage the conductor.
• Do not use this tool to cut metallic
conductors.

__________

Hand tools for skinning - auto-eject stripper

Objectives: This shall help you to
• identify an auto-eject stripper
• take care while using an auto-eject stripper.

Auto-eject strippers are used to cut the insulation from This stripper has two sets of jaws: one set grips the
electrical wire without damaging the wire strands. They insulation while the other set has cutting edges.
remove the insulation automatically. (Fig 1)

Power: Wireman (NSQF Level - 4) Exercise 1.11.72 205

When the handles are apart, both sets of jaws are open.
(Fig 2)
Precautions: While using this stripper the cable
This stripper operates automatically when the correct insulation should be put in the proper slot to
position on the blade matching the diameter of conductor avoid damage to the conductor.
in mm is selected, and the handles are compressed
together.
In an auto-eject stripper, we can select different of blades
sizes to match different sizes of conductors.

__________

206 Power: Wireman (NSQF Level - 4) Exercise 1.11.72

Power Exercise 1.11.73
Wireman - Domestic Wiring Practice - I

Demonstration and practice crimping thimbles/lugs of various sizes

Objectives: At the end of this exercise you shall be able to
• skin the cable end
• select the pressure terminal (compression connector) that suits the wire size and the terminal size
• select the pressure pliers that matches the pressure terminal size
• use the crimping tool to crimp pressure terminal(lug) at the cable end.

Requirements
Tools/ Instruments • Eyelet closing pliers 200mm with
• Pressure pliers 200mm - 1 No. former for eyelets having inner
• Electrician's knife 100mm - 1 No. dia. of 3,4,5,6,7mm. - 1 No.
• Wire stripper (manual) 200mm - 1 No. Materials
• Combination pliers 200mm - 1 No.
• Crimping eyelet, eye hole dia. 6mm - 12 Nos.
• Crimping pliers 150/200mm - 1 No.
• Crimping ferrule 4mm,10mm long - 6 Nos.
• Wire stripper auto-eject 200mm - 1 No.
• Crimping spade lug 6A - 6 Nos.
• Steel rule 300mm - 1 No.
• Crimping spade lug 10A - 6 Nos.
• Side cutting pliers 150mm - 1 No.
• Crimping spade lug 16A - 2 Nos.
• Conducting paste - 1 tube.

PROCEDURE

TASK 1: Crimping of compression connector

1 Collect the cable (fine multi-strand copper conductor).

2 Collect the spade connector suitable to the wire
thickness and terminal size 6mm dia (Fig 1, 2 & 3).

3 Select the wire stripper blade size to match the wire

thickness (auto-eject) or adjust the jaws of the
stripper. (Fig 4)

4 Strip off a length of insulation that suits the terminal size

(spade connector).(Fig 5)
Be sure not to cut or damage the wire core.

207
 Do not strip off too much insulation. (Fig 10)

5 Twist the strands of the wire lightly in the direction of

strands. (Fig 6)

Adjust the wire length so that it does not interfere

with the terminal hole. (Fig 11)

6 Select the crimping pliers that matches with the

terminal size.
9 Apply light pressure to create a light impression on the
7 Clamp the spade connector with the crimping pliers in
compression connector.
the matching position of jaws.
10 Check whether the press is located in the middle of the
8 Insert the wire far enough in the compression connector.
band of compression connector and, if necessary,
(Fig 7)
make final adjustment.
11 Apply sufficient pressure in the handle to press the
compression connector fully, as shown in Fig 12.

Do not clamp the insulation in the terminal.

(Fig 8)

12 Check whether the prepared compression/crimping

joint is firm by pulling the cable and compression
connector.
13 Repeat the crimping of compression in connectors of
various sizes of copper and aluminium conductors of
different lengths.
Strands must not stick out of the connector.
(Fig 9) Trim off the appropriate length of the skinned
cable ends to suit the compression connectors.
The types of compression connectors to be
fixed at the cable ends will be as prescribed
by your instructor. Fig 2 shows the eyelet
lug compression connected/crimped on to
flexible cable.
__________

208 Power: Wireman (NSQF Level - 4) Exercise 1.11.73

TASK 2: Crimping an eyelet.
1 Collect the multi-strand cable. 5 Trim off the excess length of the multi-strand wire after
closing the eyelet using side-cutting pliers.
2 Split the number of strands into two equal groups and
twist them. (Fig 13a) 6 Repeat the exercise with different sizes of eyelets for
cable end termination.
3 Collect the eyelet. (Fig 13b)
7 Get it checked with your insructor.
4 Fix the eyelet by placing the eyelet between the
grouped strands close to the insulation and twist the The same proceed to be repeated for crimping
free ends of the strands as shown in Fig 13c. used for thumbles.

The eyelet is then pressed on to the wire end by

the two formers of the eyelet closing pliers.
(Fig 14)

__________

Power: Wireman (NSQF Level - 4) Exercise 1.11.73 209

Power Exercise 1.11.74
Wireman - Domestic Wiring Practice - I

Practice on jointing with single and multi-stranded conductors of different wires

and cables
Objectives: At the end of this exercise you shall be able to
• mark the length of the insulation to be removed
• skin the insulation
• prepare simple twist joint
• prepar married joint in stranded conductor
• prepare 'T' joint in multistranded conductor
• prepare western union joint in bare conductor.

Requirements
Tools and Instruments/equipment • Wooden mallet 75 mm - 1 No.
• Electrician's knife with two folding • Flat file - bastard 250 mm - 1 No.
steel blades of 75 mm and 100 mm - 1 No. • Hard vice 58 mm - 1 No.
• Stainless steel rule 300 mm, with Materials
graduations on either edge cm/mm
and inches - 1 No. • PVC insulated copper cable 1/1.12 - 2 m.
• Diagonal cutting pliers 150 mm with • PVC insulated aluminium cable 1/1.40 - 2 m.
660 volts grade insulated handle suitable • Cotton cloth 30 cm square - 1 No.
for cutting hard wires - 1 No. • Sandpaper `OO' (smooth) - 1 sheet
• Combination pliers 200 mm with • PVC insulated copper cable 7/0.914/600V - 1 m.
660 volts grade insulated handles with • PVC insulated copper cable 3/0.914/250V - 1 m.
pipe grip, side cutter and two joint • Bare copper wire 4 mm 30 cm - 2 Nos.
cutters - 1 No. • GI wire 4 mm 30 cm - 2 Nos.
• Sand Paper 'O' grade - 1 sheet

PROCEDURE
TASK 1: Make simple (straight) twist joint as in Fig 1

1 Collect 2 pieces of 1/1.12 PVC copper cable of 0.5 m

length.
2 Straighten the cables. Avoid nicks in the conductor.

3 Mark 80 mm length on one end of each piece of the 6 Clean the ends with the help of a cotton cloth.
cable. Use smooth sandpaper, if necessary, to clean
4 Use the knife at 20º as shown in Fig 2. the conductor.
7 Place the conductors together, about 50 mm from the
ends. (Fig 4)

5 Remove the insulation from each conductor for a length

of 50 mm. (Fig 3)

210
8 Twist them tightly around each other in the opposite Soldering the joint and insulating it with tape
directions. (Fig 1) should be completed before putting the jointed
Pliers can be used to just grip the crossed cable in use.
conductors. 11 Show the joint to your instructor.
Each side should contain about 6 turns. 12 Cut the joint after leaving 30 mm cable from the joint.
Each turn of the conductor should closely fit to (Fig 5)
the adjacent turn.
9 Cut the excess length of the conductor using side
cutters.
10 Press the sharp edge of the conductor end and smooth
it.
13 Repeat steps 3 to 9 and make at least 4 more joints
for practice, using the remaining cable.
__________

TASK 2: Prepare married joint in 7/0.914 stranded conductors as shown in Fig 1

1 Collect 2 pieces of PVC sheathed copper cable 7/0.914

0.5 metre in leagth.
2 Mark both the the cables at 120 mm from the cable
ends.
3 Remove the insulation for 120 mm on both the cables.
Carefully remove the insulation. Do not nick
or shave the conductor.
4 Open the strands, clean the wires, and re-twist the
strands in the original direction up to 50 mm from the
cable insulation. (Fig 2)

8 Hold the cable end (that is without the binding) in one

hand and twist the strands of the other cable end over
it, one by one, closely and tightly. Each strand has to
be twisted half a turn at a time.
The direction of twist to form the shoulder
should be the same as that of the cable twist .
9 Remove the binding made in step 6.
5 Cut the centre strand of both the cables close to the
twist (about 70 mm from the free end). 10 Repeat the operation as in step 8 on the other side
with the 2nd cable end.
6 Bind on the twisted part of one cable end as shown in
Fig 3. 11 Complete the joint as shown in Fig 1 by rounding off
the twisted strands with a mallet or pliers, and cut the
7 Interlace the strands keeping the centres butt. (Fig 4) excess wires.
__________

Power: Wireman (NSQF Level - 4) Exercise 1.11.74 211

TASK 3: Prepare ‘T’ joint in multi-stranded conductor
Fig 1 shows a completed Tee joint in standard conductors.

7 Untwist the `through cable' to provide opening at the

point of tap. (Fig 6)

1 Collect two pieces of PVC insulated stranded copper

cable 7/0.91. Indicate one piece as `through cable' and
the other one as `tap cable'. 8 Insert the centre (middle) strand of the `tap cable' in
2 Mark the point of tap in the `through cable' and mark the opening of the 'through cable' as shown in Fig 7.
60 mm on either side of the tap point for the insulation
to be removed as shown in Fig 2.

3 Remove 60 mm insulation on either side of the `through

9 Wrap 3 strands of the `tap cable' around the `through
cable' from the point of tap. (Fig 3)
cable' on either side of the tap point to form shoulder
on `through cable'.
10 Wrap the strands up to 50 mm to leave a 10 mm gap
between insulation and shoulders (Fig 1) and trim the
excess length of strands.
Do not nick or shave the conductor while 11 Remove the binding from the `tap cable', wrap the centre
removing insulation. strand of the `tap cable' around the `through cable' and
4 Remove the insulation for 180 mm at the end of the wrap it in the place of the binding. (Fig 1)
`tap cable'. (Fig 4) 12 Round the ends with the combination pliers or mallet
to avoid sharp edges of the strands.
13 Collect two pieces of PVC stranded aluminium cable
19/1.12, or 19/1.63, 500 mm long and repeat working
steps 2 to 12.

5 Open the strands of the `tap cable' and clean it. Use With 19/1.2, 19/1.63 mm cable, 9 strands of the
smooth `00' sandpaper, if necessary. `tap cable' are to be wrapped on either side of
the `through cable'. Insulation that has to be
6 Re-twist the strands in the original direction up to 50 removed is 170 mm on the `through cable' and
mm from insulation, and make a binding on the twisted 250 mm on the `tap cable'.
part of the `tap cable' as shown in Fig 5.
__________

212 Power: Wireman (NSQF Level - 4) Exercise 1.11.74

Power Exercise 1.11.75
Wireman - Domestic Wiring Practice - I

Practice on marking layout on wiring boards

Objectives: At the end of this exercise you shall be able to
• mark the layout on the work station/location
• prepare PVC channel as per the marked layout.

Requirements
Tools and Instruments/equipment Materials
• Steel tape 5 m - 1 No. • PVC casing and cuppinh - 2.5 m.
• Steel Rule 300mm - 1 No. • PVC casing and capping Tee (3 way) - 2 Nos.
• Electric/Hand drilling machine • PVC Casing and capping
(capacity 6mm) - 1 No. internal coupler - 3 Nos.
• Twist drill bit 5mm - 1 No. • Colour chalk / pencil - 1 No.

PROCEDURE
1 Analyze the layout diagram Fig 1 showing the location
of fittings, accessories and their distances.
2 Draw the wiring diagram for the given circuit as per
layout plan. Check the correctness of the wiring
diagram with the help of Fig 1 (supplied by the
instructor).
3 List out the materials required for this wiring along with
complete specifications and quantity required for this
wiring .
4 Check your material list with that of supplied list.
Hand over the list to the instructor for checking
and get the approval.
5 Collect the materials as per the list.
8 Get it approval from your instructor.
6 Mark the layout as per the work station/location. Cut
and prepare the casing as per the installation plan
diagram.
7 Lay the casing and the layout as in Fig 1.
__________

213
Power Exercise 1.11.76
Wireman - Domestic Wiring Practice - I

Practice in P.V.C. insulated cable wiring on wood battern with distribution board
and number of points
Objectives: At the end of this exercise you shall be able to
• wire up on wood battens by using PVC insulated cable with distribution board
• prepare the layout for batten using with D.S
• cut and fix the batten as per layout
• fix the accessories in the concept.
• connect the accessories as per circuit diagram
• complete the wiring and test it.

Requirements
Tools and Instruments/equipment Materials
• Trainees tool kit - 1 No. • Wood batten 12 mm x 50mm x 2 mt - 2 Nos.
• Cross pein hammer 250 gms - 1 No. • Wood batten 12 mm x 50mm x 2 mt - 1 No.
• Screw driver 150 mm - 1 No. • Wood screws No. 6 x 25 mm - 12 Nos.
• Electrician knife 100 mm - 1 No. • Wood screws No. 6 x 20 mm - 12 Nos.
• Mallet 5cm dia - 1 No. • Wiring nails 12 x 6 mm - as reqd.
• Gimlet 5mm dia 200mm long - 1 No. • Wiring clips assorted/sizes - as reqd.
• Hand drilling machine 6mm - 1 No. • 4 way distribution board - 1 No.
• Drill bits 3mm to 6 mm - 1 No. • ICDP main switch 16A/240V - 1 No.
• Try square 150mm - 1 No. • 1.5 sqmm PVC insulated aluminium wire - as reqd.
• Brandal 150mm - 1 No. • Wooden round black 90 mm x 40 mm - 4 Nos.
• Combination pliers 200mm - 1 No. • 2 plate ceiling rose 6A/250V - 2 Nos.
• Hacksaw frame with blade 300mm - 1 No. • B.C. Bakelite batten holder 6A/250V - 2 Nos.
• Steel rule (300 mm) - 1 No. • 6A/240V flush type 1 way switch - 4 Nos.
• Firmer chisel 12 mm - 1 No. • Wooden switch box 100x100x25mm - 4 Nos

PROCEDURE
TASK 1: Wire up on wood batten by using PVC insulated cable with distribution board
1 Form the circuit with the required wiring accessories 10 Lay the PVC insulated cables on wood batten as per
as per circuit diagram (Fig 1) on the work bench. wiring diagram and hold the cables by using wiring clips
2 Trace the circuit and correct if it is incorrect and clip nails.
3 Mark the layout on installation practice cubicle (IPC) 11 Fix the distribution board, ICDP main switch round
or on wiring board. blocks and switch boxes.
4 Select the required wood battens as per the layout. 12 Make holes to fix the switches, ceiling roses and batten
holders.
5 Measure the length of wood batten and cut required
length for each run as per layout and make markings. 13 Terminate the cable in to accessories and mount the
switches, ceiling roses and batten holders.
6 Cut the length of wood battens as per markings.
14 Terminals other ends of cables distribution board and
While marking on the wood battens for cutting ICDP main switch.
consider the economical way to utilize the
battens without much wastage in length. 15 Make earthing to the metal parts.
7 Drill holes in the wood batten for fixing with a gap of 16 Test the circuit for insulation resistance, continuity and
60cm using drilling machine. polarity.
8 Place the wood batten in the layout markings and fixture Only after obtaining satifactory results of the
batten with batten bend, elbow and tech. above test circuit to the energised with power
supply.
9 Make half lap joints and cross lap joints if required.
17 Switch 'ON' the power supply and test the circuit for its
functions.

214
Power: Wireman (NSQF Level - 4) Exercise 1.11.76 215
Power Exercise 1.11.77
Wireman - Domestic Wiring Practice - I

Practice of wiring: A) One lamp controlled by one SP switch, (B) Two lamps
controlled by two independent switches, (C) One lamp controlled by two 2way
switches (Staircase wiring), (D) One lamp controlled by intermediate switch
from three different locations, (E) Hospital wiring, (F) Tunnel/ Godown wiring,
(G) Hostel wiring, (H) Bell Buzzer Indicator wiring, (I) Domestic wiring practice
Objectives: At the end of this exercise you shall be able to
• mark the layout on the wiring board/installation practice cubicle (IPC) for each wiring A to I
• cut the P.V.C. pipes for the required length as per the layout
• fix the accessories to the P.V.C. pipes according to the layout
• draw the wires into the P.V.C pipe and fix with saddle
• connect the wires with accessories
• wire up for the domestic light and fan wiring circuits in open P.V.C conduct
• test the wirings for their function.

Requirements
Tools and Instruments/equipment • Wood screws No. 6x12 mm - as reqd.
• Wood screws No. 6x20 mm - as reqd.
• Trainees tool kit - 1 No.
• PVC sheathed aluminium cable
• Cross pein hammer 250 gms - 1 No.
1.5 sq.mm. 250V grade - as reqd.
• Screwdriver 200 mm with 5 mm blade - 1 No.
• Flush mounting two-way switch 6A, 250V - as reqd.
• Screwdriver 150 mm with 3 mm blade - 1 No.
• One way switch 6A/250V - 4 Nos.
• Electrician's knife (100 mm) - 1 No.
• Batten lamp-holder, brass 6A, 250V - as reqd.
• Connector scrwdriver 100mm - 1 No.
• Terminal plate 2-way - 1 No.
• Gimlet 5mm dia. 200 mm long - 1 No.
• Bulb 40W, 250V, BC type - as reqd.
• Hand drilling machine 6 mm capacity - 1 No.
• PVC round block (90mm x 40 mm) - as reqd.
• Drill bit 3 mm to 5 mm - 1 each.
• PVC 'Tee' bends and elbow (Each) - as reqd.
• Try square 150 mm - 1 No.
• Marking Pen/Pencil/Chalk - as reqd.
• Brawdal 150 mm - 1 No.
• Marking thread - as reqd.
• Combination pliers 200 mm - 1 No.
• PVC insulation tape - 1 Roll.
• Hacksaw frame with blade (24 TPI) - 1 No.
• Self tapping screw (20 mm) - as reqd.
• Steel rule (300 mm) - 1 No.
• Intermediate switch 6A/250V - 1 No.
Materials • ICDP switch 16A/250V - 1 No.
• PVC pipe 19 mm - as reqd.
• PVC terminal box - 4 Nos.

PROCEDURE
TASK 1: Wire up to control one lamp by one SPT switch (A)
1 Select the tools and materials required for the task
according.
2 Mark the layout on the board. (Fig 1 & 2)

216
3 Cut the P.V.C. pipes and form the layout by firing with
saddle.
4 Identify the terminal and fixing holes of the switch and
lamp.
5 Draw the wires into pipes. Fix the round blocks for
lamp holder switch as per layour diagram. (Fig 4)
6 Form the circuit as per the schematic diagram as in
Fig 3.

Table 1
ON OFF
'S' Switch position

Lamp glow
7 Get the approval of the instructor. If necessary make
correction in the connections.
Remove all the wiring after completion of th
8 Connect the supply, check the function of the circuit
Task 1 to perform the Task 2.
and note the result in Table 1.
__________
TASK 2: Wire up to control two lamps by two indepentent switches (B)
1 Select the tools and materials as per layout diagram
and wiring. (Fig 5 & 6)
2 Repeat the steps from 2 to 7 as in task-1 amd form the
circuit as per circuit diagram. (Fig 7&8)

Table 2
Sl.No. Switch Switch L1 L2
S1 S2
1 ON ON
2 OFF OFF

3 Get the approval from instructor.

4 Switch ON the power supply from main input.
5 Test the lamp by two switches and write the status is
given Table 2.

Power: Wireman (NSQF Level - 4) Exercise 1.11.77 217

 __________

TASK 3: One lamp controlled by 2 way switches (Stair case wiring) (C)

1 Estimate the tools and materials required for the job Table 3
according to the layout (Fig 9) and the wiring diagram.
S1,S2 position up ___________________
(Fig 10).
S1,S2 position down ___________________
S1 up and S2 down ___________________
S1 down and S2 up ___________________

2 Collect materials as per the list.

3 Identify and confirm the switches received are two-way
switches only.
4 Identify the terminal points, cable entry holes and fixing
holes of the switches and batten lamp-holders.
7 Mark the layout points on the wiring board per the
5 Form the circuit as per the schematic diagram shown
installation plan. (Fig 12)
in Fig 10.

Get the approval from instructor. If necessary,

make alterations in the connections.
6 Connect the supply and check the function of the circuit 8 Cut the required length of PVC pipes as per the layout
and note the results in Table 3. marking.
Take into consideration the length of bends,
Tees and corners in appropriate places to
reduce the measured length of the P V C
conduits.
218
9 Mark the posistion of the saddles on the building and 12 Prepare the conduit entry profile, drill/make through
fix them loosely on one side only. and pilot holes in the round block and boxes.
Observe the N.E. Code for the distance between 13 Insert the cables through the cable entry holes of the
saddles. In the case of brick/concrete walls, round blocks and boxes and fix the round block and
the wooden plugs (gutties) are to be fixed flush boxes on the building.
with the walls, cemented and cured.
14 Connect the cable ends to the accessories according
10 Fix the PVC pipe and accessories in the saddle and to the wiring diagram and fix the accessories on round
tighten the saddle screws. Cut the cables according blocks and boxes.
to the wiring diagram. (Fig 10)
The completed installation should look as per
Keep an extra pipe 200 to 300 mm for the installation plan in Fig 12.
termination.
15 Test the circuit after getting the approval of the instructor.
11 Insert the cables in the pipes and fittings and push /
draw the cables to the other end of the pipes according
to the wiring diagram (Fig 11)
__________

TASK 4: Wire up to control one lamp from three different locations by intermediate switch (D)

1 Collect the accessories and materials for this exercise. 7 Mark the layout on the installation practice cubicle as
per the layout as in Fig 14.
2 Identify the mode of connections to the terminals with
respect to the position of the knob and draw the 8 Cut the required length of P V C pipes as per the layout
connection diagram of intermediate switch. marking.
3 Draw a schematic diagram to control one lamp from Take into consideration the length of bends,
three different places. (Fig 13) tees and corners in appropriate places to
reduce the measured length of the P V C
conduits.
9 Mark the position of the saddles and fix them loosely
on one side only.
Observe the N.E. Code for the distance between
saddles. In the case of brick/concrete walls,
the wooden plugs (gutties) are to be fixed flush
with the walls, cemented and cured.

4 Form the circuit according to the approved diagram on

the workbench/trainer board.
5 Show the circuit to the instructor and get his approval.
6 Operate the switches as given in Table 1 and note down
the results in Table 4.
Table 4
Position of Position of Position Condition
S1 knob S2 knob of S3 knob of lamp

   ON/OFF
  
  
   10 Fix the PVC pipe and accessories in the saddle and
tighten the saddle screws.
  
11 Cut the cables according to the wiring diagram.
   (Fig 15)
   Keep an extra 200 to 300mm for termination.
  
__________
Power: Wireman (NSQF Level - 4) Exercise 1.11.77 219
 15 Prepare the conduit entry profile, drill/make through
and pilot holes in the round block.
16 Insert the cables through the cable entry holes of the
round blocks and fix the round block on boards.
17 Connect the cable ends to the accessories according
to the wiring diagram and fix the accessories on the
T.W. round blocks.
The completed installation should look as per
the installation plan shown in Fig 16.
18 Test the circuit after getting the approval of the instructor.

12 Insert the cables in the pipes and fittings and push/

draw the cables to the other end of the pipes. (Fig 15)
For longer lengths of P V C conduit runs, use
fish wire/curtain spring to pull the cables
through the conduits.
13 Mark the entry profile of the conduit in the round block.
14 Based on the conduit entry position, position the
accessories on the round block, mark the through holes
for cable entry, and the pilot holes for fixing the
accessories.
__________

TASK 5: Wireup the lighting circuit for hospital wiring in P.V.C. conduit (E)

1 Form the circuit with required woromg accessproes as

per the schematic diagram Fig 17 on the work bench.

2 Get the circuit approved by the instructor.

If it is not correct, trace the circuit and correct
it.
3 Mark the layout on teh I.P.C as per the layout as in
Fig 18.
4 Select and cut the pipe for required length and fittings
as per layout.
5 Cut the length of the conduit as per markings and
remove the burrs.
6 Made threads in the pipes.
7 Fix the P.V.C. conduit accessories as per the layout
with a saddles.
8 Run the wires as per the circuit diagram as in Fig 19.
10 Test the wiring installation for its functioning.
9 Get the wiring checked by the instructor.
220 Power: Wireman (NSQF Level - 4) Exercise 1.11.77
TASK 6: Wire up the lighting circuit of a tunnel wiring in P.V.C. pipes (F)
1 Draw the layout and schematic diagram and estimate 11 Measure and cut the cables as per the cable route
the material required with full specification and quantity given in wiring diagram. (Fig 22)
required within, say, 30 minutes.
2 Form the circuit with the required wiring accessories
as per the schematic diagram (Fig 20) on the work
bench.

12 Provide bushes in the conduit ends.

3 Get the circuit approved by the instructor. 13 Insert the given fish wire in the pipe run for drawing the
cables.
If it is incorrect, trace the circuit and correct it.
Drawing of cables should be done stage by
4 Mark the layout on the I.P.C. as per layout given in
stage taking each run one by one and
Fig 21.
consoildating the number of cables in each
run.
14 Skin the cables and mark each cable legibly at both
ends.
15 Group the cables as per cable route and cable run
same fasten them to the fish wire.
Check the continuity of cables before fastening
the cables to the fish wire.
16 Pull the cables by means of the fish wire and at the
same time push the cables from the other end as in
Fig 23.
5 Select the required P.V.C as per layout.
6 Measure the length of P.V.C. pipes required for each
run as per layout.
Take into consideration the length of switch
boxes, bends, elbows and junction boxes to
be used in various places along with conduit
threads while taking P.V.C. measurements.
7 Cut the length of P.V.C. as per markings and remove
17 Prepare the top covers of the square metal boxes for
the burrs.
fixing the accessories by drilling through holes for cable
While marking on P.V.C. pipe for cutting entry and accessory fixing.
consider the economical way to utlize the
18 Fix the batten holders on the one-way junction boxes.
pipes without much wastage in lengths.
19 Prepare the cable ends and terminate them in
8 Prepare the TW spacers with through holes for fixing
accessories as per the diagrams (Fig 19 to 22 and 23)
on the I P C and pilot holes to fix saddles.
and cable markings done in step 14.
9 Fix the T W spacers as per layout.
20 Fix the accessories with machine screws.
10 Fix the P.V.C. pipe and accessories as per the layout
21 Close the top covers on the metal boxes.
by means of saddles.
22 Close the inspection windows of the inspection type
Knock out holes in teh square/hexagonal metal
accessories.
boxes for P.V.C. pipe terminations.

Power: Wireman (NSQF Level - 4) Exercise 1.11.77 221

23 Run the given earth wire along the conduit pipe by 24 Fix the bulbs in the batten holder.
means of earth clamps and terminate at the junction
25 Get the wiring checked by the instructor.
boxes and metal boxes.
26 Test the wiring for it's function.
Remove the paint on the surface of the conduit
and fix the earth clamps.
__________

TASK 7: Wireup the hostel wiring using P.V.C pipe (G)

1 Draw the schematic diagram ( Fig 24) and the layout

diagram (Fig 25)

11 Fix the batten holders as per the Fig 25 and terminate

the cable ends.
12 Fix the switches on the PVC switch boxes.
13 Prepare the end termination of cables and connect the
accessories as per the circuit.
14 Test the circuit after getting the approval of the instructor.
15 Wire up to control bell and buzzer independently by
using P.V.C pipe.
2 Draw the wiring diagram based on Fig 24 and 25 and 16 Collect the calling bell, buzzer and two numbers of
compare with the given wiring diagram. (Fig 26) push-button switches.
3 Draw your own wiring diagram according the layout. 17 Form the circuit according to Fig 26 either on the
4 Estimate the material required for wiring installation workbench or using a trainer board.
referring to the layout as well as the wiring diagrams. 18 Get it checked by the instructor.
5 Mark the layout on the installation practice cubical If it is incorrect, make necessary changes.
(IPC).
19 After getting the approval of the instructor, connect the
6 Prepare the PVC conduit frame as per the layout plan. main supply and test the circuit.
7 Mark the saddles position and fix them loosely as per 20 Draw your own wiring diagram and installation plan as
the layout plan. per the task and compare them with Fig 28 and 29
8 Fix the conduit pipe on the IPC with the help of saddles. respectively.

9 Insert the fish wire into the conduit pipe. 21 Determine the number of wires in each run according
to the layout diagram (Fig 27) and wiring diagram (Fig
10 Draw the cable as per the wiring diagram. (Fig 26) 29) and size of the P V C pipes in each run according
Leave an excess length of 200 to 300mm in to the number of wires.
each cable for termination.

222 Power: Wireman (NSQF Level - 4) Exercise 1.11.77

 22 Indicate the size, specifiacation and quantity of P V C
pipes, P V C conduit accessories and T.W. boxes in
the installation plan (Fig 29) and compare it with the
given list.
23 Wire up by using P.V.C. pipes and accessories by
following the steps in previous tasks.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.11.77 223

Power Exercise 1.12.78
Wireman - Domestic Wiring Practice - II

Demonstration and practice of using Row tools

Objectives: At the end of this exercise you shall be able to
• prepare the Rawl Jumber and plug
• practice on using of Rawl Tool
• fix the wooden screw on the wall using grips or gutties.

Requirements
Tools and Instruments/equipment Materials
• Rawl bit holder 6mm, 8mm, 10mm • Rawl plug - 1 box.
12mm - 1 No. • Grip plug - 1 box.
• Jumber bit 6mm, 8mm, 10mm, 12mm - 1 No. • Wooden guddies - 1 box.
• Ball been hammer 500 gm - 1 No.
• Screw driver 200mm - 1 No.

PROCEDURE
TASK 1: Prepare the Rawl jumber
1 Select the proper rawl bit holder with correct size of
jumber bit as in Fig 1.
2 Hammer the tool holder slightly by loading the tool bit,
so that the tool bit inserted up to the mark of hole in
the tool holder.

__________
TASK 2: Practice on using of a Rawl tool holder with bit
1 Mark the point of the fixing screw on the wall to be
jumbered.
2 Keep the rawl bit on the point at right angle to the wall
surface as in Fig 2.
3 Hammer the head of tool holder to make the hole.

224
4 Turn the jumber at intervals of hammer stroke in clock 5 Make the holes by repeating the hammer stroke up to
wise as in Fig 3. the required depth.
Depth of the hole varied according to the
thread of various screws in Fig 4.

__________
TASK 3: Fixing of rawl plug and screw

1 Place the rawl plug (or) grip plug (or) wooden gutties in 3 Repeat the tasks to fix various size of screws.
the hole.
4 Get the approval from instructor after complete the task.
2 Fix the screws by rotating the screw head in clock
wise, using screw driver.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.12.78 225

Power Exercise 1.12.79
Wireman - Domestic Wiring Practice - II

Demonstration and practice of casing and capping wiring

Objectives: At the end of this exercise you shall be able to
• mark the layout on the work station/location
• prepare PVC channel as per the marked layout
• fix the PVC channel and other PVC accessories
• run the cable as per the circuit diagram
• fix the top cover on the casing
• prepare & fix the PVC boxes
• mount the switches, fan regulator, socket on the switch board
• connect the end terminals to load as per the circuit diagram & test it.

Requirements
Tools and Instruments/equipment • Single pole one way switch-6A,230V
Flush type - 4 Nos.
• Wireman tool kit - 1 No.
• Electronic fan regulator - socket type - 1 No.
• Hacksaw frame with blade - 1 No.
• 3 Pin socket - 6A 250V Flush type - 1 No.
• Rawl jumper No.14 - 1 No.
• Batten lamp holder - 6A, 250V - 2 Nos.
• Screw driver 100mm - 1 No.
• Ceilling rose 6A, 250V - 1 No.
• Steel tape 5 m - 1 No.
• PVC insulated aluminimum cable
• Steel Rule 300mm - 1 No.
1.5 sq. mm - 100 mtr.
• Electric/Hand drilling machine
• Wood Screw No. 6 X12 mm - 20 Nos.
(capacity 6mm) - 1 No.
• Wood Screw No.6 X 20 mm - 7 Nos.
• Twist drill bit 5mm - 1 No.
• PVC Casing and capping Elbow -25 mm - 1 No.
Material required • PVC casing and capping Tee
(3 way) - 2 Nos.
• PVC casing and capping
• PVC Casing and capping
25mm x 10 mm - 20mtrs
internal coupler - 3 Nos.
• PVC round block - 90 mm x 40 mm - 3 Nos.
• Colour chalk / pencil - 1 No.
• T.W. box 250 mm x 100 mm with
• PVC insulation tape roll 20mm -1 Roll
Sunmica cover - 1 No.
• Terminal plate 16 Amps - 3 way - 1 No.

PROCEDURE
1 Analyze the layout diagram Fig 1 showing the location
of fittings, accessories and their distances.
2 Draw the wiring diagram for the given circuit as per
layout plan. Check the correctness of the wiring
diagram with the help of Fig 1 (supplied by the
instructor).
3 List out the materials required for this wiring along with
complete specifications and quantity required for this
wiring .
4 Check your material list with that of supplied list.
Hand over the list to the instructor for checking
and get the approval.
5 Collect the materials as per the list.
6 Mark the layout as per the work station/location. Cut 7 Drill holes in the PVC channel for fixing with a gap of
and prepare the casing as per the installation plan 60cm using drilling machine.
diagram.

226
8 Place the PVC channel in the route mark coinciding
with the jumper holes for fixing.
9 Prepare the joints on PVC channel (refer layout).
10 Fix the PVC channel on the work station as per the
layout.
11 Run the cable into the PVC channel as per wiring
diagrams (Fig 2)
12 Fix the cover on the channel.
13 Mark and cut the PVC boxes for the channel entries.
14 Drill holes for cable entry and take out cables as per
installation plan.
15 Terminate the cable in accessories and mount the
switches, regulator & socket over the switch box.
16 Test the circuit for insulation resistance, continuity test 17 Connect the circuit with supply and test it.
& polarity and get it approval from instructor.
Only after obtaining satisfactory results of the
above test, circuit to be energised.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.12.79 227

Power Exercise 1.12.80
Wireman - Domestic Wiring Practice - II

Testing of wiring installation by using Megger

Objectives: At the end of this exercise you shall be able to
• test the wiring installation for continuity or open circuit
• test the wiring installation for effectiveness of eath connection
• test the wiring installation for insulation or leakage between conductors
• test the wiring installation for insulation or leakage between conductors and earth
• test the wiring installation for correct polarity
• install fuses of correct rating in the main and branch circuits.

Requirements
Tools and Instruments Materials
• Wireman's hand tool kit - 1 Set. • Connecting prod of megger - 1 Set.
• PVC Insulated flexible cable
Equipment/Machines
23/0.2mm - 10 mts.
• Megger 500V - 1 No. • Test lamp with 15 watts bulb 240 V - 1 No.

PROCEDURE

These tests are to be carried out after completion of wiring installation or on existing wiring installation.

TASK 1: Continuity or open circuit test

1 Put the main switch 'OFF'. Remove the fuse and neutral 6 Keep all switches in the 'OFF' position.
link of the main switch and keep it in safe custody
Refer to Fig 1. The tests will have to be carried out at one
circuit at one time.
7 Identify the neutral of the individual circuits as NC1,
NC2 & NC3 and sepearate them from the common
neutral link as in Fig 1.
Test the Megger for its proper function.
8 Select a Megger 500V abd connect one terminal of
the Megger, say 'L' to the outgoing side of the circuit
LC as in Fig 1. (Phase LC1 and Neutral NC1).
9 Connect the other terminal of the Megger, say 'E', to
the identified neutral of the above circuit, say NC1.
10 Rotate the Megger as its rated speed 160 r p m.
One by one, the switches of circuit 1 should
switched 'ON' abd 'OFF' during the process of
testing.
11 Observe the Megger reading. The Megger should shown
infinity when the switch is 'OFF' and continuity which
the switch is in 'ON' for each operation.
In circuits having 2-way switches, the
2 Remove all the fuses in the distribution board. concerned switches may be operated
3 Insert all lamps in position. Connect all fans to the alternatively to ensure the correct test results.
respective ceiling roses, regulators and switches. 12 Keep the first switch in the OFF position after checking
4 Short (link) all socket outlets by linking phase and it. Then go to the second switch in the same circuit.
neutral. 13 Repeat the steps 10 to 12 of Task 1.
5 Keep the regulator knob position in the middle.

228
 After getting the correct results, remove all the
shorts in the circuit.
14 Connect the cable NC1 to the neutral link.
15 Repeat the above procedure for the other circuits.

__________
TASK 2: Testing for effectiveness of earth continuity

The resistance of the ECC should not exceed 1 Note: As the result involves human judgement
ohm whereeas the earth electrode resistance regarding the brightness of the lamp, this test
value should not exceed 5 ohms unless is not reliable unless otherwise supported by
otherwise specified as per the National field experience.
Electrical Code.
2 Take necessary steps to reduce the resistance of the
1 With a test lamp, touch one testing prod to the earth ECC and the Earth electrode resistance to an accepted
terminal of the metal body of the DB/switch/Earth value.
terminal of the 3-pin socket and touch the other testing
prod to the phase live terminal avilable at the accessory.

Result: If the test lamp glows with normal

brightness this indicates there is continuity in
the ECC and the earth electrode resistance is
reasonably good.

__________

TASK 3: Insulation resistances between conductors

1 Switch 'OFF' the main switch, remove the fuses and In circuits having 2-way switches, two test
the neutral link out. readings should be taken. One switch in each
2 Remove all the lamps from the lamp holders. (Fig 2) pair being changed over before taking the
second test, thus ensuring both the 2-way
switch (half) wires p and q shown in Fig 2 are
included in the test.
4 Put all the fuses back in the distribution board.
See that all the fuse wires are intact and of
proper rating.
5 Connect the Megger leads (E&L) to the outgoing
terminals of the main switch as in Fig 2.
6 Rotate the handle of the Megger at 160 r.p.m. Read
the insulation resistance value and enter it in Table 1.
If the Megger reading of this test is equal to or
higher than the values shown in columns 2, 3
3 Disconnect all the appliances, keep all the branch single
and 4 of Table 1 or otherwise one megohm
pole switches in the 'ON' position.
and above, the insulation resistance of the
installation is satisfactory. If the test result is
not satisfactory follow the steps 11 to 14 given
in insulation test to earth (Task 4).

Power: Wireman (NSQF Level - 4) Exercise 1.12.80 229

 Table 1
Sl. Standard value of Calculated value of Value of ins- Measured insulation Remarks
No. insulation resistance insulation resistance ulation resistance value
as per B.I.S. rules as per IE rules resistance between
as per thumb conductors
50 Supply voltage in volts
   m
No. of points in the circuit Leakage current

in megohm in megohm rule = one in megohms

megohm or
above

__________

TASK 4: Insulation test between conductors and earth

From the insulation resistance value we can 6 Connect the 'L' terminal of the Megger to the short
calculate the leakage current or vice versa. terminal of the main switch.

1 Put the main switch OFF. Remove the fuses of the 7 Connect one lead marked 'E' of the Megger with earth
main switch and keep them in safe custody. terminal of the main switch.

2 Insert all the fuses in the distribution board. See that Aternatively the earth connection of the
all the fuses are intact and of proper rating. Megger can be connected to the conduit/lead
sheathing/earthed water mains as in Fig 4.
3 Insert all lamps in position. (Fig 3)

8 Disconnect all the domestic appliances from the some

and short the socket before testing with the Megger.
9 Rotate the handle of the Megger at 160 r p m (Apply
note the reading of the Megger).
4 Close all the single pole switches 'ON'.
In circuits having 2-way corridor switches, two
In an incomplete installation, the conductors test readings should be taken, one switch in
at each outlet (points and switch position) must each pair being changed over before taking
be joined together. the second test thus ensuring that both the 2-
way switch (half) wires are included in the test.
5 Short the outgoing terminals of the main switch with a
piece of wire. 10 Check the readings with the following recomments
values.
care should be taken to see that the shorting
link is used in the installation side only. Service a Standard value as per BIS
main supply is available in the bottom portion
b Value as per IE rules
of the switch and any accidental contact with
the main supply would be dangerous. C Value as per thumb rule

230 Power: Wireman (NSQF Level - 4) Exercise 1.12.80

Standard value as per BIS This test will only include the portion of the
installation between the main switch and the
50 bus-bars of the distribution board.
  m
No. of points in the circuit 12 Sometimes the poor insulation resistance value may
be due to the poor insulation of the cable. Then replace
Where the switch and lamp holder socket are
the cable.
taken as individual points.
13 If the best result is found to be low still, investigate any
IE Rules states that leakage current in the
leakage between the cable and the earth at the main
insulation should not exceed 1/5000th part of
switch or at the DB. Rectify the defect.
the full load current of the installation.
If the result in procedural step 11 (Task 4) is
Full load current of installati on found to be OK, proceed as below.
Leakage current 
5000 14 Insert the fuse in one circuit, connect the respective
neutral wire to the link in the DB and repeat steps 8 to
Calculated insulation resistance value as per IE rules.
10 (Task 4). If the reading is found to be OK, add another
fuse.
Supply voltage in volts
 in m 15 Connect the respective neutral wire to the link in the
Leakage current
DB i.e. you are adding one more circuit, and repeat
The measured value of insulation resistance with the steps 8 to 10 (Task 4) till you read low insulation
Megger should either be equal or higher that the calculated resistance value. Then the circuit you added las has
calculation resistance value as per IE rules. low insulation resistance. Investigate the cause and
rectify the defect.
Value as per thumb rule
Normally the defect could be traced in ceiling
However, as a thumb rule, if the measured insulation roses, switches or socket connections.
distance value is one megohm or above for the whole
installation, it is acceptable. 16 Enter the recommended/ calculated/ measured values
in Table 2.
11 If the values obtained are not sufficiently high withdraw
all the fuses at the distribution fuse board, disconnect 17 Remove all the shorting links in the main switch and
neutral, it is acceptable. wall sockets.

Table 2
Sl. Standard value of Calculated value of Value of ins- Measured insulation Remarks
No. insulation resistance insulation resistance ulation resistance value
as per B.I.S. rules as per IE rules resistance between
as per thumb conductors
50 Supply voltage in volts
   m
No. of points in the circuit Leakage current

in megohm in megohm rule = one in megohms

megohm or
above

__________
TASK 5: Polarity test

If the insulation resistance values are 2 Open all the switch covers.
satisfactory, then only energise the installation. 3 Switch 'ON' the supply.
1 Keeping the main switch in the 'off' condition remove 4 Connect one terminal of the test lamp prod to any earth
all lamps from the lamp-holders. (Fig 5) point within the installation.

Power: Wireman (NSQF Level - 4) Exercise 1.12.80 231

 5 Hold the insulation portion of the other test prod and
touch the prod alternatively to any one terminal of the
switch.
In the case of two-way switches, operate the
switching knob of the pairs alternatively to
check the polarity.
If the test lamp lights, the switch is correctly
connected. If the lamp does not light then the
switch is connected in the neutral cable.
6 Make necessary alterations in the connection such
that the switch is in the phase wire.

The earth pin of the socket outlet or main

switch earth whose effectiveness is tested as
per procedure stated in Task 3.

__________

TASK 6: To test the polarity in sockets

1 Keep the socket in the 'OFF' position as in Fig 6. 3 Touch the neon terminal to the right side terminal of
the socket as in Fig 6b, while touching the other end of
a neon tester with your finger.
The neon tester should not glow while the
switch is in OFF position. If it glows this
indicates that the phase is not controlled
through the switch.
4 Proceed as stated below, if the neon tester does not
glow.
5 Switch 'ON' the socket switch keeping the Neon tester
in the right side terminal as in Fig 6b.
If the neon tester does not flow, when the switch
is the 'ON' position, correct the wiring.
Sometimes the neon tester glows dimly or does
not glow at all even after the switch is 'ON'.
This indicates that the neutral wire is connected
to the right side and correction of the wiring
connection is necessary.
2 Check the neon tester for its proper working. If the neon tester is not glowing on both the
terminal check for AC supply failure.
Normally while using a neon tester on a
terminal you have to touch the wall or ground
with your bare hand or feet.

__________
TASK 7: Install fuses of the correct rating in the main and branch circuits

1 Switch 'OFF' the mains (Fig 7 No.1) 3 Determine the rating of the fuse. The rating of the most
fuse should be determined by the lowest rating of one
2 Check the existing fuse wire in the fuse carrier of the
condition shown below.
main switch. (Fig 7 No.2)
a Rating of service main cables.
If the rating of the fuse cannot be determined,
remove the same. b Rating of the main cable connected incoming side
of the main switch. (Fig 7 No.3)
c Rating of the main cables connected to outgoing
side of the main switch. (Fig 7 No.4)

Power: Wireman (NSQF Level - 4) Exercise 1.12.80

232
 d Rating of the energy meter. c Rating of the load current, in the branch circuit
determined by connected load.
e Rating of the main switch. (Fig 7 No.4)
d Normally for lighting the fuse rating is 5 amps.
f Rating of the load current of the installation
determined by the connected load.
4 Replace the main fuse wire of known rating.
5 Check the correctness of the neutral link.
6 Check the circuit fuses in the distribution board. ( Fig
7, LC1 to LC4)
7 Determine the rating of the fuse in each circuit. Say
LC1 NC1, LC2 NC2, LC3 NC3 and LC4 NC4.
The rating of the circuit fuse should be
determined by the lowest rating of any one of
the conditions shown below.
a Rating of the branch circuit cable.
b Rating of the flexible cord used in ceiling roses etc.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.12.80 233

Power Exercise 1.12.81
Wireman - Domestic Wiring Practice - II

Demonstration and practice in cutting and threading conduit pipes

Objectives: At the end of this exercise you shall be able to
• measure and cut the conduit pipe according to the requirements
• prepare the conduit pipe ends for threading, and fasten in a pipe vice
• cut the threads on heavy gauge metal conduit according to requirement using a conduit die set
• mark the position of bending on the conduit pipes
• bend the conduit pipe by manual cold bending
• set the bending machine according according to the size of the conduit pipe
• bend the conduit pipe according to the requirements with the bending machine
• prepare the conduit for manual hot bending (filling and plugging).

Requirements
Tools and Instruments/equipment Materials
• Pipe vice 50 mm - 1 No. • Conduit pipe 20 mm dia. 3 m long - 1 No.
• Steel rule 300 mm - 1 No. • Lubricant - coconut oil - 100 g.
• Hacksaw with 24 teeth per 25 mm (for a batch of 16 trainees)
blade (24 TPI) - 1 No. • Chalk piece - 1 No.
• Blow lamp, 1 litre, with kerosene - 1 No. • Cotton waste - as reqd.
• Flat file bastard 200 mm - 1 No. • Matchbox - 1 No.
• Half round file bastard 200 mm - 1 No. (for a batch of 16 trainees)
• Reamer 16 mm - 1 No. • Wooden plugs suitable to plug
• Oilcan 200 ml - 1 No. 16 mm holes - 2 Nos.
• Conduit stock and dies for 20mm • River sand - as reqd.
conduit - 1 Set. (for a batch of 16 trainees)
• Wire brush 50 mm - 1 No.
• Conduit bending machine (bench type)
with 20 mm collet and guide - 1 Set.

PROCEDURE
TASK 1: Preparation of conduit pipe for cutting

Assume the job needs a 300 mm long conduit

drp, and a standard length pipe of 3000 mm is
only available. Normally both the ends of the
standard length will have threads. To make the
required conduit drop the standard length of
3000 mm pipe is to be cut for a length of 300
mm and threaded again at one end.
Cutting could be done either by pipe cutters or
with a hacksaw. In practice cutting with a
hacksaw is popular and the method is
explained belwo.
1 Measure 300 mm from the threaded end of the pipe
and mark it with chalk as in Fig 1.
2 Open the jaw of the vice and insert the pipe so that it is
horizontal and parallel to the jaw serration.
3 Keep the chalk mark of the pipe within 100 mm of the
vice as in Fig 2.
4 Close and tighten the vice jaw.

234
5 Select a hacksaw with a blade having 24 teeth per
25.4 mm (24 TPI) as in Fig 3
Check that the hacksaw blade is firmly
tightened in the frame and that the teeth point
in the forward direction.

6 Take up the hacksaw and position yourself as in Fig 4

with your left shoulder pointing in the direction of the 11 Saw with steady, even strokes, keeping the blade up-
cut. right and square to the cut as in Fig 7.

Note the position of the feet, which allows for

free and controlled movement of the body
when cutting.

12 When getting near to the end of the cut, the must be

supported with your left hand as un Fig 8.
Support the conduit free end to prevent blade
of the hacksaw from being damaged.

7 Grip the hacksaw handle with the right hand and position
the hacksaw blade on top of the cutting line.
8 Prepare to cut by guiding the blade with the thumb of
your left hand exactly on the cutting line against the
saw blade as in Fig 5.

13 Use a reamer or half round file to remvoe the burrs as

in Fig 9.

9 When the initial cut has been made, move the left hand
to the front end of the hacksaw frame and use both
hands for the cutting operation as in Fig 6.
10 When sawing, use the full length of the blade,
increasing gradually the pressure on the forward stroke
and releasing the pressure as the blade is drawn back.

Power: Wireman (NSQF Level - 4) Exercise 1.12.81 235

14 Use the flat portion of a half round file to smoothen
sharp edges. (Fig 10)
15 Clean the hacksaw and vice and keep them in
respectively places.

__________

TASK 2: Cutting of the each on conduit pipe

1 Open the jaw of the vice and insert the pipe so that it is Assembly drawing for the quick cut stock and
horizontal and parallel to the jaw serrations. dies is given in Fig 13. Die size is engraved on
2 Keep the end of the tube within 150 mm of the vice. the die itself. Check the size with that of the
pipe. (Handle of the stock is not shown in the
3 Close and tighten the vice as in Fig 11. figure).

4 File and end of the tube flat and chamfer the outer
edge to an angle of about 20º as in Fig 12.
Make the depth of the cha mfer equal to the
pitch of the thread (1.5 mm for conduit)

6 Insert each half of the die in the cap (stock) with the
chamferred threads (leading faces) being adjacent to
the guide.
7 Screw the guide into position.
8 Adjust each adjusting screw equally to make the die
5 Choose the correct die and stock suitable for the pipe halves centralized to the pipe axis.
to be threaded.
9 Slide the stock guide over the end of pipe, adjust the
adjusting screws such that the dies just grip the pipe
evenly on both sides.

236 Power: Wireman (NSQF Level - 4) Exercise 1.12.81

10 Apply pressure to the stock and keep the handles at The lubricant allows the die to cool of the heat
right angles to the pipe as in Fig 14. developed. Thereby the edges stay sharp and
produce a better finish of the reach.
13 Make one or two complete turns in clockwise direction.
Check whether the stock is at right angle to
the pipe axis.
14 Frequently, as indicated by the increased resistance
of rotation, ease the handle back in anticlockwise
direction for half a turn.
Reverse turning is necessary to break off long
cuttings and to clear the cutting edges of the
die.
15 Apply the lubricant at frequent intervals.
Use a brush to remove the metal burrs from
the die.
16 Remove the stock. Check the length and fit of the thread
11 Rotate the handles clockwise in a plane at right angles by screwing on the female fittings (coupling etc).
to the pipe axis as in Fig 15.
The length of thread should be sufficient to fit
half way into the couplings and fully into the
other fittings.
17 If the thread is not smooth (i.e. tight in the fittings)
mount the stock and tighten the adjusting screws by
half turn evenly and repeat working steps 25 to 31.
18 Remove any burrs or sharp edges from inside the end
of the pipe with a reamer or a round file as in Fig 16
and file off any sharp edges.
19 Clean the die stock and the vice. Keep them in the
respective places.

12 Apply a lubricant to the part to be threaded after the

thread has been started.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.12.81 237

Power Exercise 1.12.82
Wireman - Domestic Wiring Practice - II

Cold and hot bending of pipes

Objectives: At the end of this exercise you shall be able to
• mark the position of bending on the conduit pipes
• bend the conduit pipe by manual cold bending
• set the bending machine according to the size of the conduit pipe
• bend the conduit pipe according to the requirements with the bending machine
• prepare the conduit for manual hot bending (filling and plugging).

Requirements
Tools and Instruments/equipment Materials
• Pipe vice 50 mm - 1 No. • Conduit pipe 20 mm dia. 3 m long - 1 No.
• Steel rule 300 mm - 1 No. • Lubricant - coconut oil - 100 g.
• Hacksaw with 24 teeth per 25 mm (for a batch of 16 trainees)
blade (24 TPI) - 1 No. • Chalk piece - 1 No.
• Blow lamp, 1 litre, with kerosene - 1 No. • Cotton waste - as reqd.
• Flat file bastard 200 mm - 1 No. • Matchbox - 1 No.
• Half round file bastard 200 mm - 1 No. (for a batch of 16 trainees)
• Reamer 16 mm - 1 No. • Wooden plugs suitable to plug
• Oilcan 200 ml - 1 No. 16 mm holes - 2 Nos.
• Conduit stock and dies for 20mm • River sand - as reqd.
conduit - 1 Set. (for a batch of 16 trainees)
• Wire brush 50 mm - 1 No.
• Conduit bending machine (bench type)
with 20 mm collet and guide - 1 Set.

PROCEDURE
TASK 1: Preparation of conduit pipe for bending
METHOD 1: Bending the conduit pipe by manual method (Cold bending using bending block)

1 Mark the place of bending in the conduit pipe with chalk.

Poorly seam-welded pipes are not suitable for
bending as they may split while bending.
2 Decide the angle of bending according to the type of
job.
For easiness you can draw a sketch on the floor
showing the required bend.
3 Choose a wooden block, approximately having
dimensions 1500 x 150 x 50 mm.
4 Bore a hole in the centre of the block at a distance
1/3rd length from the top using a drill 2 mm larger than
the conduit to be bent as shown in Fig 1.
5 Chamfer both sides of the opening in the block.
6 Insert the conduit into the hole such that the marked
portion is just in the centre of hole.
7 Place the hands on the conduit close to the wooden
block as in Fig 2. This prevents the conduit from bending
where not required.

238
8 Press downwards bending the conduit only slightly. 11 Continue this procedure until the bend has been
completely formed as per requirement. Check the angle
9 Move the conduit through the hole for a very short
of bend with the sketch on the floor. Fig 4
distance. Keep the conduit in the same line, and do
not rotate it in the hole. Ensure that the conduit does not twist during
the bending operation.
One way of doing this is to draw a line long
the axis of the conduit with chalk and to position
the conduit.
10 Bend the conduit slightly as before as in Fig 3.

__________

METHOD 2: Bending the conduit pipe by manual method (Cold bending using a hickey)

1 Mark the place of bending in the conduit pipe with chalk. 5 Hold the conduit firmly to the ground with your feet and
give enough leverage to the hickey stick to form the
2 Decide the angle of bending according to the
bending as in Fig 6.
requirement.
6 Slightly move the hickey and repeat the process till
3 Choose the hickey to suit the size of conduit.
the complete bend is formed.
4 Slip the hickey over the conduit as in Fig 5.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.12.82 239

METHOD 3: Bending the conduit pipe by bending machine (Cold bending)

There are several types of bending machines

available. They are classified as portable,
bench-fitted, hydraulic etc. Here a bench-fitted
bending machine is used.
1 Mark the place of bending in the conduit with chalk.
2 Decide the angle of bending according to the
requirement.
3 Choose the correct collet (Former) and guide and fix it
in the bending machine as in Fig 7. 6 Rotate the handle in the indicated direction Fig 9 form
the bend.
Stop rotation when the angle of bend is
sufficient.
7 Loosen the handle and remove the conduit by sliding
out.

Each bending machine ahs certain limitations

with respect to the diameter of the pipe.
Follow the manufacturer's instruction for fitting
the collect and guide.
4 Insert the conduit between the collet and the guide as
in Fig 7
5 Position the conduit pipe such that the marking is place
at 45º to the initial position between the collet and guide
as in Fig 8.
__________

METHOD 4: Bending the conduit pipe by manual method (Hot bending)

This method of bending is useful for heavy

gauge pipes or for seam welded pipes of poor
quality.
1 Mark the place of bending in the conduit with chalk.
2 Determine the angle of bend according to the
requirement.
3 Prepare two wooden plugs as in Fig 10.

5 Fill the conduit pipe with dry river sand tightly and plug
the other end of the pipe with the other wooden plug.
(Fig 12).

4 Plug one end of the conduit with a wooden plug tightly

as in Fig 11.

240 Power: Wireman (NSQF Level - 4) Exercise 1.12.82

 Collect the sand in a bucket. The sand will be
very hot and may cause injuries to someone
Do not use wet sand as the steam generated who comes in contact with it.
during the heating of conduit may cause and
explosion. 9 Insert a small ball of cotton waste in the conduit and
push it to the other end of the conduit with a stiff rod to
6 Use a blowlamp to heat the portion to be bent as in clean the inner surface of the conduit.
Fig 13.
10 Remove the cotton waste.
7 Bend the conduit slowly and steadily using a wooden
block or hickey when the conduit is still hot.
8 After the bend is completed unplug the pipe and remove
the sand.
__________

Power: Wireman (NSQF Level - 4) Exercise 1.12.82 241

Power Exercise 1.12.83
Wireman - Domestic Wiring Practice - II

Fitting of conduit accessories

Objectives: At the end of this exercise you shall be able to
• identify the accessories for fitting
• cut and thread conduit pipes
• assemble the conduit pipes as per layout.

Requirements
Tools and Instruments/equipment Materials
• Pipe vice 50 mm - 1 No. • Conduit pipe 20 mm dia. 3 m long - 1 No.
• Steel rule 300 mm - 1 No. • Lubricant - coconut oil - 100 ml.
• Hacksaw with 24 teeth per 25 mm (for a batch of 16 trainees)
blade (24 TPI) - 1 No. • Chalk piece - 1 No.
• Flat file bastard 200 mm - 1 No. • Cotton waste - as reqd.
• Half round file bastard 200 mm - 1 No. • Conduit away & 3 way junction - 1 each.
• Oilcan 200 ml - 1 No. • Conduit 1 way junction - 4 Nos.
• Conduit stock and dies for 20mm • ¾ inch conduit pipe clamp - 12 Nos.
conduit - 1 Set.
• Wire brush 50 mm - 1 No.

PROCEDURE
TASK 1: Preparation of conduit pipe by cutting and threading
1 Measure 300 mm from the threaded end of the pipe
and mark it with chalk as in Fig 1. 5 Cut the conduit pipe for the required length and remove
the burrs. (Fig 3 & 4)

2 Open the jaw of the vice and insert the pipe so that it is
horizontal to the jaws.
3 Tighten the vice jaw.
Ensure that the hacksaw blade is firmly
tightened in the frame and that teeth point in
the forward direction.
4 Prepare to cut by guding the blade with thumb of your
left hand exactly on the cutting line against the saw
blade as in Fig 2

242
6 Choose the correct dies and stock suitable for the pipe
to be threaded.
7 Cut external thread on the conduit ends. Which are to
be fitted. (Fig 4)
8 Assemble the die set as in Fig 5 by
a Inserting each half of the die in the cap with leading
faces.
b Screw the guides
c Centeralized the die set to pipe axis.
9 Apply pressure to the stock and keep the handles at
right angles to the pipe. 11 Apply the lubricant to the part to be threaded after the
10 Rotate the handles clock wise. thread has been started.

__________

TASK 2: Assemble the conduit as per layout

1 Fix the conduit pipe and acessories like bend, elbow, 2 Get the approval from the instructor after complete the
tec, 4 way junction etc with the help of saddles as per task.
the installation plan.
Fix the saddles at a distance of 75mm from the
centre of the block.

__________

Power: Wireman (NSQF Level - 4) Exercise 1.12.83 243

Power Exercise 1.12.84
Wireman - Domestic Wiring Practice - II

Preparation of conduit threads using different fittings and use of running threads
wiring in conduit, using metal clad 3 pin plug, Earthing the conduit using earth
clips and earth wire
Objectives: At the end of this exercise you shall be able to
• draw the circuit and wiring diagram to prepare the layout for conduit wiring
• cut the metal conduit as per markings and cut external threads on metal conduit
• fix metal conduit accessories and electrical accessories
• draw the cables through metal conduits and make termination providing earth
• test the metal conduit wiring installation.

Requirements
Tools and Instruments/equipment • Wood screws and machine screws - as reqd.
• Metal clad socket box with breaker
• Combination pliers 200 mm - 1 No.
20A/240V - 2 Nos.
• Screw driver 200mm x 5mm - 1 No.
• Metal conduit inspection 'T' 19 mm - 4 Nos.
• Screw driver 150mm x 3mm - 1 No.
• Metal conduit bend 19 mm - 1 No.
• PIpe vice 50 mm - 1 No.
• Tinned for 19 mm conduit suitable for
• Steel rule 300 mm - 1 No.
19 mm conduit - 2 Nos.
• Hacksaw frame with blade 300 mm - 1 No.
• PVC aluminium cable 1.5 sqmm
• Flat file bastard 200 mm - 1 No.
1.1 kv grade - 18 mtrs.
• Half round file 2nd cut 250 mm - 1 No.
• One way flush type switch 6A/240V - 2 Nos.
• Oil can 250 ml - 1 No.
• One way flush type switch 16A/240V - 2 Nos.
• Ball pein hammer 0.5 kg - 1 No.
• Ceiling rose 2 plate 6A/240V - 1 No.
• Hand drilling machine 6mm - 1 No.
• Bakelite batten holder 6A/240V - 1 No.
• Drill bits 3mm to 6 mm - 1 No each.
• BC bulb 100W/240V - 1 No.
• Scriber 200 mm - 1 No.
• Colour chalk - 1 No.
• Conduit stock and dies set 19mm
• Terminal plate 16Amps 3 way - 1 No.
and 25 mm - 1 Set.
• GI Fish wire - 6 mtrs.
• Cleaning brush ½" - 1 No. • PVC bushes suitable for 19mm conduit - 20 Nos.
Materials • Conduit check but 19 mm - 10 Nos.
• Heavy gauge metal conduit 19mm - 6 m. • Lubricant oil - 100 ml.
• Metal box 90 mm x 90 mm - 4 Nos. • Cotton waste - as reqd.
• Metal conduit GI saddles 19 mm - 25 Nos.

PROCEDURE
TASK 1: Draw the circuit and wiring diagram and prepare the layout as per wiring diagram

Assume the metal conduit wiring consists as

per the diagram Fig 1.
1 Select and collect the required tools accessories and
materials.
2 Draw the circuit diagram.
3 Form the circuit with required accessories as per circuit
diagram on work bench.
If it is incorrect trace the circuit and correct it.
4 Prepare wiring diagram according to the circuit
diagram.
5 Mark the layout as per wiring diagram on installation
practical cube or on wiring board.
__________

244
TASK 2: Cut the metal conduit as oer markings and cut external threads on metal conduit

1 Form the circuit with metal conduit accessories and 9 Again follow the above steps and prepare the metal
other electrical accessories on the marked layout. conduits as per required length and required nos.
2 Measure the length of metal conduits required for each 10 Keep the end of pipe within 150 mm from the vice jaw
run as per layout and make markings. and tighten the vice as in Fig 5.
While marking on the metal conduits for cutting
consider the economical way to utilize the
metal conduits without much wastage in
length.
3 Open the jaw of pipe vice and insert the pipe so that it
is horizontal and parallel to the jaw serrations.
4 Keep the mark of the pipe within 100mm from the vice
jaw as in Fig 2.

11 File the end of conduit flat and chamfer the outer edge
to an angle to about 20º as in Fig 6.

5 Grip the hacksaw handle with right bend and position

the hacksaw blade on top of cutting line.
6 Take up the hacksaw and position your self as in Fig 3
and saw with steady, even strokes keeping the blade
upright and square to the cut.

12 Choose the correct stock suitable for the pipe to be

threaded.
Assembly drawing for the quick cut stock and
die is given in Fig 7.

7 When getting near to the end of cut the conduit must

be supported with your left hand and finish the cut.
8 Use half round file to remove the inside burrs as in
Fig 4.

Power: Wireman (NSQF Level - 4) Exercise 1.12.84 245

13 Insert each half of the die in the stock cap with the
chamferred threads as leading faces being adjacent
tio the guide.
14 Screw the guide in to position.
15 Adjust each adjusting screw equally to make the die
halves centralised to the pipe axis.
16 Slide the stock guide over end of conduit evenly on
both sides.
17 Apply pressure to the stock and keep the handles at
right angles to the conduit as in Fig 8.
18 Rotate the handles clockwise in a plane at right angles 20 Finish the thread and remove sharp edges and burrs
to the conduit. from inside the ends of conduit by using half round file.
19 Apply the lubricant to the part to be threaded after 21 Clean the die stock and vice.
thread has been started.
__________

TASK 3: Fix the metal conduits by using metal conduit accessories and fix various electrical accessories

1 Screw the conduit pipes into conduits accessories as 3 Fix the metal boxes where ever required and fix with
per the layout. metal conduits.
2 Lay the conduits on the layout and fix by means of 4 Fix metal clad socket boxes and otehr electrical
saddles. accessories.
Knock out the holes in the square/hexagonal 5 Provide bushes in the conduit ends.
metal boxes for conduit pipe terminations as
6 Get it checked by the instructor.
in Fig 9.

__________

TASK 4: Draw the cables through metal conduits, make termination and earth the metal conduit installation

1 Insert the fish wire in the conduit and run for drawing
cables.
2 Measure and cut the cables as per the cable route
given in the wiring diagram.
Drawing of cables should be done stage by
stage, taking each run one by one and
consolidating the number of cables in each
run.
3 Cables and mark each cable regibly at both ends.
4 Group the cables as per cable route and cable runs
and festen them to the fish wire as in Fig 10.
5 Pull the cables by means of the fish wire and at the
same time push the cables from the other ride.
246 Power: Wireman (NSQF Level - 4) Exercise 1.12.84
6 Run 14 SWG GI wire along the outside of the conduit 12 Earth the earth pin of 3 pin metal clad sockets.
by means of earth clips.
13 Fix the bulb and ceiling fan.
7 Fix the earth clips at the frequent interval of the conduits
14 A complete installation looks as in Fig 11 & 12
and earth the junction boxes and metal boxes.
8 Fix the ceiling roses and batten holders on the one
way junction boxes.
9 Prepare top covers of the square metal boxes for fixing
the accessories and drilling through holes for cable
entry.
10 Terminate that cable ends to respective accessories.
11 Fix the accessories with machine screws and close
the top covers of metal boxes.

__________

TASK 5: Test teh metal conduit wiring installation

1 Check whether the cables used in the installation have 5 To check IR value between earth and wiring installation
proper continuity by using megger. connect the terminal E of the megger to the earth point
of the system and terminal L of megger with any
2 Check circuit fuses whether in order or not, if necessary
condutor in turn at the main board.
rewire the fuse.
6 After ascertaining the insulation resistance values are
3 Keeping all the switches in 'OFF' position and connect
the megger terminal E to the Line Wire 'L' to the more than 1 M then switch 'ON' the power supply
corresponding neutral wire. The megger will read more after getting instructor approval.
than 1 M . If megger read zero or very low value 7 Check each circuit for its proper function including metal
confirm the short circuit and rectify the fault. clad socket.
4 Keep all the fuses in base and switches bulbs, fan in
closed position.
__________

Power: Wireman (NSQF Level - 4) Exercise 1.12.84 247

Power Exercise 1.13.85
Wireman - Illumination

Installation of - Neon Sign tube, Mercury vapour (H.P. & L.P.), Sodium vapour,
Halogen Lamps, single tube, double tube, Metal halide lamps. Emergency light
Objectives: At the end of this exercise you shall be able to
• connect, install and test the neon sign tube with transformer
• connect, install and test mercury vapour lamp
• connect a sodium vapour lamp with accessories and test it
• connect the halogen lamp and install into parabolic reflectors
• connect a single tube flourescent lamp with accessories and install and test it
• connect a doube (twin) tube flourescent lamp and install it
• connect and test a high pressure metal halide lamp
• connect and check the functioning of the emergency light.

Requirements
Tools and Instruments • Filiter capacitor 5 F 400 VAC - 1 No.
• H.T. Leads - 4 m.
• Screwdriver 100 mm - 1 No.
(HT cable, used for spark plug)
• Cutting pliers 150 mm - 1 No.
• Connecting lead 2.5 sq.mm - as reqd.
• Test lamp 60W, 230V - 1 No.
• Plastic stand 40 mm length 5 mm dia - 13 Nos.
• Megger 500V - 1 No.
• Phosphor-bronze clips - 13 Nos.
• Connector screwdriver 75 mm - 1 No.
• 18 S.W.G zinc sheet box
• Flat nose plier 150 mm - 1 No.
610 cm x 530 cm x 25 cm painted
• Multimeter - 1 No.
with black colour paint - 1 No.
• Wire stripper 150 mm - 1 No.
• M.S. sheet 18 SWG boxes
• Voltmeter AC 250V - 1 No.
510 cm x 12 cm x 5 cm - 4 Nos.
• Soldering iron 10W, 240V - 1 No.
• Painted with synthetic enamel glossy-
• Tweezer 150 mm - 1 No.
finish colour paint. (The colour should
• Insulated wire cutter 150 mm - 1 No.
match the colour of the neon lamp
• Hand drilling machine 6.5 mm cap - 1 No.
• Bar chart (Showing cause for accidents) - 1 No.
Equipment/Machines • MV lamp-holder (Goliath screw type) - 1 No.
• MV lamp choke 250 watts/230V - 1 No.
• Neon lamp (letter I) - 500 mm length
• MV lamp (HP) 250 watts/230V - 1 No.
and 12 mm dia - 1 Nos.
• Capacitor 4 MFD/380V - 1 No.
• (Letter T) - 1250 mm length and
• Connecting leads - as reqd.
12mm dia - 1 No
• Halogon lamp 1000w/240V - 1 No.
• A step-up transformer 230/2000V,200VA - 1 No.
• C.T.S. connecting cable 7/20 (4mm2) - as reqd.
• Parabolic Reflector suitable for
• Insulation tape 20 mm adhesive - as reqd.
1000W Halogen lamp - 1 No.
• HP MH bulb 60W, 250V - 1 No.
• Igninter for SV lamp - 1 No.
• Test lamp 250V 60W - 1 No.
Materials • Connecting leads - as reqd.
• I.C.D.P. switch 240V, 16A - 2 Nos. • 1.15W Emergency light - 1 No.
• R.F. coil 20 mH - 1 No.

PROCEDURE
TASK 1: Connect, Instal and test a neon sign with transformer

1 Check the neon tube mounting in the tracks and its Short the H.T. leads before conducting the tet
proper supporting by clips as in Fig 1 & 2. on L.T. side. This avoids shock due to accidental
2 Make electrode connections between the tubes using contact.
nickel leads.
3 Test the transformer for continuity and instulation.

248
 4 Make the necessary connections as per the circuit as
in Fig 3.
Use cables having an insulation rating, atleast
4 times of the operating voltage of the neon
sign.
5 Earth the H.T. side of transformer, the body of
transformer and metal frame of the neon sign.
6 Switch ON S1 and S2 respectively and check for neon
light glowing. Observe for no sparking due to loose
connection at the neon tube.
7 Switch OFF S2 and S1 respectively to turn the set off.

Table 1
Item/Part No. Name of part/description Specification No. Remarks
T Step up transformer 230/2000V 100VA 1
L1 R.F. choke 20 mH 1
C Capacitor 5 F 1
F Fuse 15A 4
S2 Fireman's switch D.P. 16A, 240V 1
S1 Main switch D.P. 16A, 240V 1
Power: Wireman (NSQF Level - 4) Exercise 1.13.85 249
TASK 2: Connect and test mercury vapour lamp

1 Read the specification of the mercury vapour lamp and

the choke from the markings. (Fig 1)

2 Connect the H.P.M.V. lamp in series with the 60W 240V

bulb and test in 240V AC supply. Check whether the
series test lamp glows.
3 Test the choke for its working condition.
4 Assemble the accessories (choke, holder and
capacitor) in the fitting, following the manufacturer's
instructions.
5 Connect the accessories as per circuit diagram, Fig 2
(Pictorial diagram Fig 3) using the recommended type
of termination. Count at the location

Choose the tapping of the choke suitable to 8 Observe the recommended method and procedure
the rated supply system voltage. specified by the manufactrer in the installation manual.

6 Fix the bulb in the holder and test the working of the Do not after the specificaions recommended by the
lamp with the supply voltage. manufacturer because it should be strong enough to
support the weight of the fitting.
Ensure the fitting is properly earthed at the
earthing terminal provided, before testing. 9 Connect the M.V. lamp fitting to the supply. The method
depends on the system of wiring, location of fitting etc.
A modern M.V. lamp with a built-in-resistor
needs to external accessories to be connected Ensure that the supply line is dead (not live),
as discussed above. It can be connected as we before making the connections.
do an incandescent lamp. 11 Fix the bulb in the holder securely and refit the cover.
Installation of the M V lamp fitting 12 Switch 'ON' the supply and wait until the high pressure
7 Assemble, connect and test the M.V. lamp fitting on a mercury vapour lamp glows with its full brightness. Then
table for its working. The remove the cover and bulb. switch off the supply.

__________

TASK 3: Connect and test sodium vapour lamp

1 Read the specification from the markings on the leak Follow strictly the manufacturer's instructions.
transformer, choke and bulb.
4 Give connections as per diagram shown in Fig 1.
2 Check the transformer and choke with a test lamp for
shorts and open. Use the recommended type of termination only.

3 Assemble the accessories (choke, leak transformer 5 Choose the appropriate voltage tapping suitable to the
and lamp-holder) in the fitting. supply voltage. (Fig 1)

250 Power: Wireman (NSQF Level - 4) Exercise 1.13.85

 7 Test the working of the assembled fitting by connecting
it to the mains.
8 Note the time taken for the bulb to give full illumination.
9 Repeat the above steps for a high pressure sodium
vapour lamp. Connect as per the diagram shown in
Fig 2.

6 Fix the bulb in the holder.

Ensure the fitting is properly earthed.
__________

TASK 4: Connect the halogen lamp and install it with the parabolic reflector and test it
1 Take 1000W/240 V halogen lamp and test the contact 4 Install the halogen lamp with reflector at suitable place
pins and filament for its continuity by using multimeter. where the light has to be focused.
2 Connect the components of the halogen lamp with the 5 Assemble the following fluorescent tube accessories
reflector. in the fitting base. Refer to the sketch. (Fig 3)
3 Fix the halogen lamp in the reflector. 1) Holders for tube 2) Starter-holder 3) Choke

6 Connect the accessories as in Fig 4 (for a single tube

light). Also install the tested starter.
7 Test the filament on both sides of the fluorescent tube
for its continuity as in Fig 5. Discard the fluorescent
tube with open or fused filament in either side.

Power: Wireman (NSQF Level - 4) Exercise 1.13.85 251

 The fixing of the tube to the wall, ceiling or
tubular post should be strong enough to
support the weight of the fitting.
The installed fitting must be below the level of
the ceiling fan to avoid the flickering effect of
the shadow.

8 Fix the bulb in the holder.

• Firstly you have to make sure that the slt in the
inner parts of the holder is turned to the proper
position.
• Then insert both the ends (pins) into the holder of
the fittings on either side of the tube. One end is
shown in Fig 6. Push the socket pins all the way
into the fitting until you feel that you can turn the
tube in the sockets. 11 Connect the tube light fitting to the ceiling rose.
• Turn the tube at both ends in any one direction by a Check the supply at the ceiling rose. Switch
quarter turn. Stop when you feel that the pins have off the supply before making any connection.
'snapped' into position.
12 Fix the fluorescent tube in the fitting.
Be careful not to bend the pins at either end of
Use a stable ladder and a helper to hold the
the tube.
ladder while you are working on the ladder.
9 Test the tube light assembly for its working.
13 Switch 'ON' the supply and obseve the glow of the tube.
10 Follow the recommended method and procedure If the tube is not glowing, check for proper housing of
depending on the type of wiring. starter and tube.
__________
TASK 5: Assemble, test and install the Twin-tube light-series/parallel connection (600mm/20W) and
Industrial fitting assembly and installation
1 Test the choke starter, fluorescent lamps and capacitor 7 Connect the accessories as per the circuit diagram
for their working. (Fig 2) for the two 1200mm tube lights.
2 Assemble the choke, capacitor, lamp-holders, starter-
holders in position in the lamp fitting for twin the feet.
3 Connect the accessories as per the circuit diagram.
(Fig 1)

Terminate the leads to a connector for

connecting to the supply.
4 Fix the starters and the fluorescent tubes.
5 Connect the fitting to the supply and test for its
functioning.
If it is not glowing adjust the starter and the
tube.
For Twin-tube light-parallel connection (1200 mm)
6 Repeat the steps 1 to 2.
252 Power: Wireman (NSQF Level - 4) Exercise 1.13.85
 11 Mount the fitting, suspending from the desired location
and providing the required length of wires to connect to
the supply in the wiring system.
Ensure the mounting is firm and does not give
way because of the weight of the fitting itself.
12 Connect the supply leads to the fitting from the ceiling
rose or junction box.
13 Switch ON the supply and test for its working.

8 Fix the starters and fluorescent lamps, connect the

fitting to the supply and test.
For Industrial fitting assembly and installation
9 Repeat the steps 7 to 9 for assembling the industrial
fitting (Fig 4) by connecting 3.8 Fd in series iwth any
one of the tube circuits as in Fig 3 and 3.15 Fd across
the supply.
10 Remove the tubes from the fitting before installing.

__________
TASK 6: Connect and test high pressure metal halide lamp
1 Read the specifications of the given Halide lamp as Check whether the series test lamp glows. If
Fig 1. the test lamp glows it means that HPMV lamp
2 Collect the required accessories. is in good condition.

3 Connect the HPMH lamp is series with a 60W, 250V 4 Connect as per the circuit diagram and test with 240V
incandescent lamp as in Fig 1, and test with 240V supply.
AC supply. 5 Measure the current and voltage. Calculate the power
and verify with the rated values.
Voltage : ___________________Volt
Current : ___________________ Amp
Power : ___________________ Watt

Power: Wireman (NSQF Level - 4) Exercise 1.13.85 253

TASK 7: Connect and test the emergency tube light circuit
1 Trace the circuit diagram of an emergency tube light 7 Solder the components as per diagram.
circuit as per diagram in Fig 2 and 3.
8 Check the connection with respect to the schematic
2 Identify the each component of the ciruit. diagram.
3 Test the collected components for their condition. 9 Switch on the AC supply for charging the battery.
4 Arrange the components (except the battery) on the 10 Check the glow of red LED which is an indication for
PCB to meet the technical requirement and aesthetic the presencce of AC supply.
sense.
After charging the battery, switch 'OFF' the AC
5 Draw the layout of the components on the PCB. supply put 'ON' the tube switch and observe
the functioning of the emergency tube light and
6 Mount the components on the PCB in their respective
also see the glow of green LED indicator.
places and fix the heat sink over the power transistor
after applying silicon grease.

__________

254 Power: Wireman (NSQF Level - 4) Exercise 1.13.85

Power Exercise 1.13.86
Wireman - Illumination

Practice on decoration lighting

Objectives: At the end of this exercise you shall be able to
• select lamps/sequential control for light decoration
• design lighting layout for running light
• design layour for rotating light
• connect the motor for 3-points running light (sequential control motor)
• connect lamp circuits in the electronic sequential controller
• test for open circuit and short circuit.

Requirements
Tools and Instruments Materials
• Multimeter - 1 No. • Cams - 3 Nos.
• Brushes - 3 Nos.
Equipment/Machines
• Connection leads flexible - as reqd.
• Single phase motor FHP with • Cam drive arrangement with shaft - 1 No.
reduction gear - 1 No. • Lamps 240V, 15W, BC - 54 Nos.
• Lamp holder, brass BC - 54 Nos.
• DPST knife switch 16A 240V - 2 Nos.
• Electronic sequenctial controller
240V operation outout load 5 to 10 A
with speed and intensity control - 2 Nos.

PROCEDURE
TASK 1: Connect and test decorative light and check running light effect

1 Connect the lamps, switches and the flasher motor as

in Fig 1.
2 Keep the D.P.S.T. switches S1 & S2 open.
3 Close the D.P.S.T. switch S1 and start the flasher motor
(sequential light controller).
4 Close the D.P.S.T switch S2 and observe the make
and break contacts 1,2,3 and 'ON' 'OFF' operations of
the 3 lamp banks.
Do not touch live wires.
5 Open the D.P.S.T. switches S2 and S1.

__________

255
TASK 2:

1 Prepare the lighting design as in Fig 2.

2 Close the D.P.S.T. switch S1 and observe the lighting.
3 Increase the speed of operation by operating the speed
control.
4 Adjust the intensity of light-adjusting the knob on the
electric sequential controller.
5 Reduce the speed and intensity of the lighting system.
6 Open the D.P.S.T. switch S1.

__________

256 Power: Wireman (NSQF Level - 4) Exercise 1.13.86

Power Exercise 1.13.87
Wireman - Illumination

Practice on using LUX Meter

Objectives: At the end of this exercise you shall be able to
• identify the lux meter with specifications
• set the meters for measurement
• measure the light intensity at different places.

Requirements
Tools and Instruments/equipment
• Lux meter with all accessories
Needle indicator (meter) - 1 No.

PROCEDURE
1 Select the area where the light intensity to be 5 Switch OFF the lights and complete the reading.
measured.
6 Measure the open space light intensity (sun range
Note down the light fittings with wattage of light available outside and record it.
and their type.
Caution: Do not exposure the meter in direct
2 Switch OFF all the light and measure the light intensity light; it may cause error in reading.
at 4 corners and centres of the Room, by using lix
meters. Record it. (Fig 1) Fig 1

3 Switch ON one light and measure the light intensity

record the reading.
4 Switch ON all the lights available in the room and
measure the light intensity at all places.
Record Sheet
1 Note down the specification of the Lux meter.
Make :
Light Range :
Temperature :
Relative Humidity :
Sound :
Size of the room /
Area in sq. metres :

Sl.No. No.of Light & Watts Position Reading in all sides / Corner / Centre
Corner1 Corner 2 Corner 3 Corner 4 Centre

1 L1 Watts: ON/OFF

2 L2 Watts: ON/OFF

3 L3 Watts: ON/OFF

4 L4 Watts: ON/OFF

5 L5 Watts: ON/OFF

__________

257
Power Exercise 1.13.88
Wireman - Illumination

Installation and testing of CFL Lamps and LED Lamps

Objectives: At the end of this exercise you shall be able to
• connect a CFL lamp and test it
• carry out a quick test using a meter to find its condition
• measure current and voltage drop for reasonable brightness
• calculate the required limiting resistor for a given LED as output indicator in a power supply.

Requirements
Tools and Instruments/equipment Materials
• Test lamp 60W, 240V with loads - 1 No. • CFL lamp-15W, 240V - 1 No.
• Insulated cutting plier 150 mm - 1 No. • Connecting leads - as reqd.
• Screw driver 200 mm - 1 No. • Battern/pendant holder - 1 No.
• Connecting screw driver 75 mm - 1 No. • Assorted LEDs of different types
• Trainees kit - 1 No. size and colours (per batch) - 20 Nos.
• DC milliammeter 0-50 mA - 1 No. • Red colour LED - 1 No.
• Ohmmeter/multimeter - 1 No. (FLV117 or EQUV)
• DC Voltmeter 0-10V - 1 No. • 220 , 1/4 W resistor - 1 No.
• 1 k potentiometer - 1 No.
• Lug board general purpose 20 points - 1 No.
• PVC sleeve (assorted size) - as reqd.
• PSU variable 30 V1A - 1 No.
• Patch cords - as reqd.
• Soldering paste - as reqd.
• Solder - as reqd.
• Data book on LEDs - 1 No.

PROCEDURE
TASK 1: Connect the Compact Flourecent Lamp (CFL) lamp and test

1 Mark the specifications of the CFL lamp.

2 Identify the poits CFL lamp and collect the required
accessories as in Fig 1 note down in Table 1.
3 Connect the CFL lamp in series with a 60W, 250V
incandescent lamp and test with 240V AC supply.
4 Check whether the series lamp glows. If the test glows
it seams that CFL lamp is in good condition.
5 Then connect the CFL lamp and test with 230 V AC
supply.
6 Note the starting current and normal running current in
the record book.

258
 Table 1
Sl.No. Label No. Name of the part of CFl

1
2
3
4
5
6
7
8
__________

TASK 2: Identification of type, colour of LED and quick test of LEDs using ohmmeter
1 Take one of the given assorted LEDs. Enter its label 4 Set the ohmmeter/multimeter in x 1W range. Connect
number in Table 1. the meter prods across the LED terminals and check
the condition of the LED.
2 Identify and record type, size and colour of the LED
from the data book. Observe the glow closely as the glow of LED may be
dimension due to weak batteries of the meter.
The present day LEDs are available with no
colour encapsulation. Colour could be seen Hints
only when they are 'ON'.
A good single colour LED glows when the meter
prods are connected in one direction as in
Fig 2a. It does not glow when the prods are
reversed as in 2b.
A good double colour LED flows in one colour
when the meter prods are connected in one
direction and glows in a different colour when
the prods are reversed.
A defective LED does not glow when the meter
prods are connected in either direction.
5 Repeat step 1 to 4 atleast five more LEDs of different
types.
3 Identify the anode and cathode leads of the LED
following the hints given in Fig 2a. Put red sleeve wire 6 Ensure that +ve of DC supply is connected to the anode
on the anode lead of LED as in Fig 2b. of the LED; otherwise the LED may become defective.
7 Switch ON the PSU, Adjust 1k pot such that tht LED's
glow is reasonably bright and visible. Record the current
passing through the LED in Table 1.
8 Measure and record the voltage drop V1 across the
LED.
9 Take the pot to the maximum resistance position
(minimum circuit current). Switch OFF PSU. Take out
the LED.
10 Repeat steps 2 to 5 for atleast five LEDs of different
types and colours.
11 Get your work checked by your instructor.

__________
Power: Wireman (NSQF Level - 4) Exercise 1.13.88 259
Power Exercise 1.14.89
Wireman - Industrial Wiring - I

Practice usage of application and type insulating materials

Objectives: At the end of this exercise you shall be able to
• practice usage of application and type insulating materials.

The instrument has to explain the trainees

about the various types of insulation materials
and its area of application.
The trainees has to tabulate the various insulation material
used in wiring process based on the type and area of
wage and get it checked by the Instructor.

260
Power Exercise 1.14.90
Wireman - Industrial Wiring - I

Measurement of insulation resistance, of commercial and industrial installation

Additional practice in conduit wiring
Objectives: At the end of this exercise you shall be able to
• draw the layout and wiring diagram of power wiring
• wire up for power wiring in metal conduit
• measure the insulation resistance value of industrial power wiring
• measure the insulation resistance value of a commercial wiring.

Requirements
Tools and Instruments Materials
• Wireman tool kit - 1 Set. • 63A TPIC switch 500V - 1 No.
• Conduit die set with dies and • 32A TPIC switch 500V - 1 No.
cover 25 mm - 1 Set. • DOL starter 3 HP - 1 No
• Hack saw frame with blade - 1 No. • Heavy gauge conduit pipe 25mm - 2 length.
• Oil cane - 1 No. • Conduit bend 25mm - 6 Nos.
• Pipe vice 50mm - 1 No. • Conduit saddles 25mm - 30 Nos.
• Reamer suitable for 25mm pipe - 1 No. • Earth clips 25mm copper - 25 Nos.
• Round file bastard 200 mm - 1 No. • Wood screw 35mm x No 6 - 1 Box.
• Cleaning brush - 1 No. • Wood screw 25mm x No 5 - 1 Box.
• Megger 1000V - 1 No. • Lock nut 25mm - 6 Nos.
• Megger 500V - 1 No. • Flexible conduit - 5 m.
• Hand drilling M/C 6mm capacity - 1 No. • Flexible conduit ripple with lock nut - 5 Nos.
• Drill bit 6mm - 1 No. • PVC copper wire 4 sq.mm - 50 m.
• Drill bit 4mm - 1 No. • PVC bushes 25mm - 10 Nos.
• Test lamp 60W - 1 No. • T.W. guties - as reqd.
• Copper / G.I. earth wire No 8 SWG - 10 m.
Equipment/Machines
• AC 3 Phase squirrel cage induction
motor 3 HP, 415V - 1 No.

PROCEDURE
TASK 1: Practice of power wiring in metal conduits
1 Draw the layout and estimate required materials Fig 1.

261
2 Collect all the materials and verify. 9 Terminate the cable ends and connect it in 32A main
switch and starter.
3 Cut and thread the metal conduit as per layout.
Use lugs and ferruls for termination.
4 Fix and side of the saddle in the wall.
10 Run the earth wire on the surface of conduits.
5 Assemble the conduit frame, fit in the saddle and screw
the other end of the saddle. Use earth clips for proper contact.
6 Fix the main switch and starter. 11 Terminate and connect the cable ends at motor and at
63A mains.
7 Draw the 4 sqmm PVC copper cable from 63A main
switch to motor via starter and main switch. 12 Check the continuity and insulation resistance value.
8 Fix properly the motor in the bed. 13 Get the connection approved by your instructor.
Double earth must be provided to motor, main 14 Switch ON the power and test the motor for proper
switch and starter. running.
__________

TASK 2: Practice in measure the insulation resistance value of an industrial power wiring
1 Collect a 1000V megger and check its performance. 2 Connect megger terminals as in Fig 2.

3 Measure the insulation resistance and note down the 5 Change the megger connections as in Fig 3 to measure
reading in Table 1. the IR value between phase and earth and note down
in Table 2.
4 Connect the megger in between B.C.R. phase and R&Y
phase and note down the readings in Table 1. Table 2

Use 1000V megger for power installation Sl.No. Connection IR value in Megaohms
testing.
1 R&N
Table 1
2 Y&N
Sl.No. Phase IR value in Megaohms
3 B&N
1 B&R

2 B&Y 6 Draw the readings to your instructor and get it approved.

3 R&Y

262 Power: Wireman (NSQF Level - 4) Exercise 1.14.90

 __________
TASK 3: Practice in measuring the insulation resistance value of an commercial wiring
1 Collect a 500V megger and check its wiring. Table 3
2 Connect the megger as in Fig 4a. Sl.No. Connection IR value in Megaohms
Before connection get approval from your 1 Phase & neutral
instructor. Switch OFF the mains and inverter
2 Phase & earth
before connecting megger.
3 Measure and note down the readings in Table 3. 5 Get the readings checked and approved by your
instructor.
4 Disconnect and reconnect as in Fig 4b and note down
the reading in Table 3. Insulation resistance value must be more than
1 megaohm.

__________
Power: Wireman (NSQF Level - 4) Exercise 1.14.90 263
Power Exercise 1.14.91
Wireman - Industrial Wiring - I

Industrial power wiring involving single phase and 3phase motors with switches
and starters
Objectives: At the end of this exercise you shall be able to
• prepare the layout for fixing single phase motor
• prepare the layout for fixing 3 phase motor
• estimate the materials required as per the layout
• fix the accessories, MCB, starter etc.,
• wire up the panel board, motor with metal conduit
• test the motor.

Requirements
Tools and Instruments/equipment • DOL starter OLR range 4-8A, 3-phase - 1 No.
• 14SWG metal conduit pipe 25mm - 9m.
• Wireman's tool kit - 1 No.
• Metal conduit inspection bend 25mm - 3 Nos.
• Electric drilling m/c capacity 6 mm - 1 No.
• 2.5 sqmm PVC copper conductor cable - 40m.
• Drill bit -4mm - 1 No.
• 1.5 sqmm PVC copper conductor cable - 5m.
• Drill bit -6mm - 1 No.
• 14SWG copper earthwire - 0.5 kg.
• Megger 1000V - 1 No.
• Earth clamp 25mm - 12 Nos.
• Conduit die set 25mm - 1 No.
• GI conduit saddles 25mm - 12 Nos.
• Panel type MI voltmeter 0-600V - 1 No.
• Wood screws No. 6 x 20mm - 25 Nos.
• Panel type MI voltmeter 0-15A - 1 No.
• Wood screws No. 8 x 45mm - 15 Nos.
Materials • Wooden plugs - 20 Nos.
• IC panel board (70cm x 50cm x 10cm) - 1 No. • Wooden base plant for conduit pipe 25mm - 12 Nos.
• Rotary switch for voltmeter - 1 No. • Machine screws 4 x 25mm with washers - as reqd.
• Rotary switch for ammeter - 1 No. • Metal flexible conduit pipe - 1m.
• Four pole MCB 16amp with metal box - 1 No. • Flexible conduit coupling - 2 Nos.
• Fuse unit flush type 6A - 3 Nos. • 25mm check nut - 6 Nos.
• Neon indicator lamp with holder • Insulation tape 25mm of 5m - 1 Roll.
(panel type) - 3 Nos.
• SP switch 6A (flush type) - 3 Nos.

PROCEDURE
TASK 1: Wire up a AC single phase motor with main switch and starter
1 Inspect the floor area and determine the location of the
motor and panel board to be installed.
2 Draw the layout diagram as in Fig 1 and estimate the
materials required.
3 Mark on the panel board according to the layout as in
Fig 1 for fixing accessories.
4 Drill holes for mounting meter and also drill hole
wherever necessary to draw wires as marking on the
panel board.
5 Fix the accessories as per layout.
6 Wire up the panel board as in Fig 2.

264
 Use cup washers and coach screws for fixing
the panel board on wall and don't over tight
the screws.
10 Mark the layout for concealed GI system from panel
board to meter board as in Fig 4.
11 Measure the total (Vertical & horizontal) distance from
panel board to meter board on ground and wall.
12 Cut the GI pipe and form the threads on both ends and
fix GI elbows according to horizontal distance by digging
the floor and install the GI pipe.
13 Fix vertical conduit pipe on the wall by using saddle
clamps.

7 Mark and dig the wall to fix the wooden plugs so as fix
the panel board by using cement as in Fig 3.
After fixing the wooden plugs on wall time gap
to be maintained for proper cutting (atleast 24
hours).

14 Fire the vertical conduit pipes and horizontal GI pipe

by using proper sealing compound for water proof.
15 Connect the GI pipe after running earth wire along GI
pipe and conduit pipe from meter board to panel board.
16 Measure the distance from panel board to motor.
17 Mark and cut and thread the metal conduit pipe and GI
wire according to layout fix by using saddle from panel
board to motor.
18 Draw the wire through pipes from meter board panel
board and panel board to motor.

8 Mark horizontal and vertical line between wooden plugs 19 Connect the wires to the meter, starter and motor
on wall and measure the distance (horizontal and terminals.
vertical) between centre point of the wooden plugs. 20 Test the installation by megger.
9 Mark according to the above measurements on panel 21 If the above test is found satisfactory give incoming
board, and drill holes on four corners for fixing the panel supply.
board on wall.
22 Check the motor for its proper running.
__________
TASK 2: Wireup for a 3 phase meter with main switch and starter
1 Estimate the required materials and accessories for 5 Mark the conduit run route and accessories position
the given layout as in Fig 1. on the work station.
2 Work out the cost of the above materials and Ascertain the location of offset wherever it is
accessories. necessary.
3 Collect and physically check the items for their good 6 Prepare the conduit pipe runs as per the given layout.
condition.
7 Fix the wooden base blocks for conduit pipe run.
4 Draw the wiring diagram as in Fig 2.
8 Fix the conduit pipe runs on the wooden base blocks.
Power: Wireman (NSQF Level - 4) Exercise 1.14.91 265
9 Draw the cable length through the conduit pipe and 11 Mark the accessories on the panel board as per the
refer the wiring diagram. given layout.

10 Run the earth wire along with the conduit pipe and fix it 12 Drill holes on the panel for fixing the accessories and
using earth clamps. cable entries.

13 Mount the accessories on the panel and fix the panel Refer the name plate of the motor to know the
on the frame. type of connection and full load current.
14 Wire up the panel board for MCB, DOL starter, fuses, 17 Test the insulation with megger for insulation and earth
pilot lamp and other accessories as shown in diagram. continuity.
If required use flexible metal conduit pipes at 18 Adjust the OLR of DOL starter to the full load current of
the terminaltion points of the pipe run to the motor and also ensure the correct size of the fuses
connect the motor. for the pilot lamps.
15 Connect the earthwire with the earth bolts/screws 19 Ge the connections approved by the instructor.
provisions given in starter, motor, panel frame and MCB
box. 20 Energise the installation and test the motor and other
panel accessories.
16 Prepare the cable terminal leads and complete the end
connections as per the circuit diagram. (Fig 2)

__________
266 Power: Wireman (NSQF Level - 4) Exercise 1.14.91
Power Exercise 1.15.92
Wireman - Commercial Wiring

Inverter wiring./ Control panel wiring / multi-storeyed building wiring

Objectives: At the end of this exercise you shall be able to
• draw the layout of wiring diagram according to the position of building plan
• prepare the using details and estimate the material required for wiring installation
• select the proper rating of marks and rating of battery
• install the bus bar and other accessories as per the layout diagram
• run the trunk cable as per the circuit diagram
• prepare and fix the terminal boxes
• mount and connect the accessories in the installation
• test the installation.

Requirements
Tools and Instruments/equipment • ICTP main switch 3-phase 16A 415V - 4 Nos.
• Phase change over switch 3-phase
• Hack saw frame with blade - 1 No.
16amps 415V - 1 No.
• Ball peen hammer 500g - 1 No.
• ELCB T.C. 100mA 16amp 240V/400V - 1 No.
• Rawl jumper No.14 - 1 No.
• MCB 6amp 240V - 4 Nos.
• Screwdriver 200mm No.8 - 1 No.
• Sheet metal box for fixing the MCB,
• Screwdriver 200mm No.6 - 1 No.
ELCB & phase change over switch
• Terminal connector screwdriver 150mm - 1 No.
with indicator - 1 No.
• Cutting plier (insulated) 200mm - 1 No.
• PVC channel 25mm x 12 mm - 4 length
• Steel tape 5m - 1 No.
each 10 ft
• Steel rule 300mm - 1 No.
• PVC channel 25mm elbow inner & outer - as reqd.
• Electric/Hand drilling machine - 1 No.
• SPT switch, flush type 6A, 240V - 12 Nos.
• Electrician knife - 1 No.
• Sunmica sheet 300 x 250mm - 1 No.
• Twist drill 5mm - 1 No.
• PVC copper 1.5 sqmm cable 600V - 1 coil.
• Cold chisel 180mm - 1 No.
• PVC copper 4 sqmm cable 600V - 1 coil.
• Firmer chisel 20mm - 1 No.
• Wooden plugs - as reqd.
• Try square - 1 No.
• Wood screws 20mm, 25mm, 35mmxNo.6 - as reqd.
• Flat file 240mm - 1 No.
• Two plate ceiling rose 6A 240V - 6 Nos.
Materials
• PVC round block 25 x 75 mm - 8 Nos.
• ICTP main switch 3-phase 60A, 415V - 1 No. • Insulation tape 5m 20mm - 1 Roll.
• Main bus bar chamber 3-phase 60A • Bare copper wire 10SWG & 16SWG - as reqd.
415V - 1 No.

PROCEDURE
TASK 1: Prepare the wiring installation details and draw the wiring diagram

1 Plan of the complete multi story building in given Fig 1. 3 Installation layout of mains and sub mains in Fig 1.
2 The requirment of electrical fittings and their positions
for one floor.

267
 __________

268 Power: Wireman (NSQF Level - 4) Exercise 1.15.92

TASK 2: Details of civil work
The officce building have 3 store eyes each floor having 4
rooms.
Channel runs at a height of 220cm from the floor level.
Requirements
1 The building is provided with 3- phase supply and load
should be distributed as below.
Floor Name of phase

First R
Second Y
Third B
Note: If failure of pahse happened, then use
the change over switch keeping the load at
3 Complete wiring is done in looping system.
minimum.
4 Each room in all the 3 floors have same loads as give
2 PVC Channel wiring system proposed with proper
in the layout diagram.
protective devices (ELCB, MCB's & earth)
5 The loads in each room forms one separate circuit.
__________

TASK 3: Channel wiring

1 Draw the PVC channel layout diagram over the given
Fig 1 according to the requirement.
2 Show the PVC channel run layout diagram to your
instructor and get it his approval.
3 Draw the circuit and wiring diagram for the copied layout
in a separate sheet.
4 Show the completed wiring diagram to your instructor
and get his approval.
5 Determine the size & type of cables for each run
according to the load and their respective length.
Take care of permissible voltage drop in the cable.
6 Estimate the size and length of cable required for the
complete wiring.
• 1.5 sqmm PVC insulated coppe conductor cable 8 Mark on the cubicle as per the installation layout given
100m. in Fig 2.
• 4 sqmm PVC insulated copper conductor cable 9 Cut the PVC channel as per layout given in Fig 2.
100m. 10 Drill holes in the PVC channel for fixing at end distance
7 Select the suitable size channel according to the type, using drilling machine.
size and no. of cables and also estimate the respective 11 Place the channel on th marked route & mark holes for
length. fixing.
PVC Channel 12 Prepare the joints on the PVC channel.
It may not be possible to get a building for 13 Fix the channel as per the layout.
wiring as per the Fig 1. Hence the trainees may
be asked to do the wiring in a wiring board/ 14 Run the cable in the PVC channel as per the weight
cubicle as per Fig 2. diagram.
Use separate coloured cable for earth
connection in fans, regulators and earth pin of
sockets. Use extra 5cm in all cable ends as an
allowance.

Power: Wireman (NSQF Level - 4) Exercise 1.15.92 269

15 After completion of the wiring test the insulation
resistance as per IE rules.

16 Select the suitable rating of the inverter considering 23 Put grease (or) vasaline on the battery terminals for
the total connected load in that multi story buidlings. reducing the terminal connection.
like fan, lamp etc.
24 Complete the connection. Take the output from the
The rating of the inverter should not exceed inverter output and use it to power the load.
80% capacity of the inverter key. (for a 100w
25 Connect the ON/OFF switch on the wall panel from
inverter, total load should not be more than
the phase output pin of inverter output socket. (Fig 1)
80W).
26 Connect one common (or) Neutral line of both inverter
17 Select the right place to install the inverter.
output and mains A.C. supply.
The place for installation for inverter should
27 Connect only one wire for the phase line from the
be nearer to the D.P. switch and the energy
inverter output.
meter position.
28 Give connection to one bulbm one fan 9A).
18 Select the correct place to install battery, which is near
to the inverter. 29 Connect the other devices in the room i.e. the tube
light, fan (B) and.
19 instal the inverter and battery close to each other.
30 Show your connectiona and get it approved by your
Do not provide the battery away from inverter.
instructor.
If should be close to the inverter because it
helps in reducing the current loss due to 31 Check the operation of inverter during power then power
resistance of wire. returns.
20 Make wiring connection to the inverter. If the main supply is 'ON' the load connected
to the inverter will get the main A.C supply,
21 Connect the positive terminal of the battery (i.e. red
and the other devices which are directly
wire) to the place provided for the positive terminal on
connected to the mains AC supply will also
the inverter.
work on the main supply.
22 Connect the negative terminal of the battery (i.e. black
During power shut down, the devicces which
wire) to the place provided for the negative terminal of
are directly connected to the mains A.C will
the inverter.
stop functioning and the devices connected to
When connecting battery terminals to the the inverter will keep on working on the
inverter use special auto wires, do not use inverter output. When the mains A.C supply
common 3/20 (or) 7/20 wires and ensure that returns the inverter will again connect the load
the battery is fully charged. to its output.

270 Power: Wireman (NSQF Level - 4) Exercise 1.15.92

 __________

Power: Wireman (NSQF Level - 4) Exercise 1.15.92 271

Power Exercise 1.15.93
Wireman - Commercial Wiring

Introduction to LAN (Local Area Network) wiring

Objectives: At the end of this exercise you shall be able to
• select the accessories required for LAN wiring
• set and connect, the computers, printers, servers and storage devices with suitable cables
• test the LAN connections.

Requirements
Tools and Instruments/equipment Materials
• Multi purpose crimping tools - 1 No. • RJ 45 cable - as reqd.
• T-20 Screw driver - 1 No. • MIO cover with LAN board assembly - as reqd.
• Flat blade screw driver 150mm - 1 No.
• Electrician knife 100mm - 1 No.
• Ethernet cables - as reqd.

PROCEDURE
TASK 1: Setting up of small LAN to connect computers to the internet

1 Install router using a CAT-5 cable to connect it to be For a connection, you might be connecting
internet source. (Fig 1) directly to an antenna or to a modem
connected to the antenna.
2 Connect wired computers to routers.
The router will act as the centre of star network
you may also need to install the software with
router on to one of the network computers.
3 Connect a switch to the router.
The switch connects to one of the ports in the
router (via) a CAT-5 cable.
4 Connect wireless computers to the router.
If you have wireless router and computers with
wireless adaptors connect each computer
individually to the router.
5 Connect wireless access point to the router.
Make sure you also take into account maximum
allowable cable lengths in deciding which type
of cabling to be used.

__________

272
Power Exercise 1.15.94
Wireman - Commercial Wiring

Installation of single phase and 3 phase ON line / OFF line UPS wiring
Objectives: At the end of this exercise you shall be able to
• install single phase UPS wiring to name
• install 3 phase UPS wiring and test it.

Requirements
Tools and Instruments/equipment Equipment/Machines
• Cutting plier 200 gm - 1 No. • Single phase ON line/OFF line
• Hack saw frame with blade - 1 No. UPS unit 240V/AC - 1 No each.
• Ball pen hacksaw 500 gm - 1 No. • 50 Hz 300 VA - 1 No each.
• Rawl jumps No. 14 - 1 No. • Unit battery 12V/120 AH -5 KVA - 1 No.
• Screwdriver 100 mm - 1 No. • 3 Phase UPS 415V/5KVA - 1 No.
• Screwdriver 200 mm - 1 No. • Connecting wires - as reqd.
• Steel rule 300 mm - 1 No. • UPS components - 1 No.
• Hand wiring machine LPMH - 1 No
• DEE knife 100mm - 1 No.
• Measuring tape - 1 No.

PROCEDURE
TASK 1: Installation of single phase UPS and test it

1 Select the correct capacity of UPS for the required 2 Select the size of the cable based on the full load
load by following the steps given below. current.
• List all the equipment to be protected by the UPS Size of the cable should be from battery to
for single and two room. UPS, not below 25mm2 to 35mm2.
• List the voltage and current rating of each device in 3 Select the best location and design the space for the
single and two room. selected UPS system prior to install.
• Calculate the total VA capacity by multiplying 4
voltage and current of each device.
• Add 10 to 20% of load for future extension.
__________

TASK 2: Wiring for ON line UPS (single and two rooms)

1 Read and interpret the name plate details of the given 4 Connect the wiring supply to main double pole switch
ON line UPS. (DP) input terminals. (Fig 1)
2 Note down in Table 1 Use read wire for phase and black wire for
neutral.
Table 1
5 Connect the output terminals main supply to input
Model __________________
terminals of the UPS. (Fig 1)
Type __________________
6 Connect the outgoing phase (L) wire directly to the
Paner rating __________________ incoming terminals of the switches of the given load
(for one room) Fig 1.
Input and output voltage __________________
7 Connect the neutral from the outgoing terminal from
Battery rating __________________
UPS to the socket outlet neutral point and loop to all
3 Identify the input and output terminals and interpret the load. (Fig 1)
the centre UPS.

273
 10 Repeat the above steps from 1 to 9 as in Fig 2 and
complete the wiring for 2 rooms considering the locals
and size of the UPS.
11 Test the wiring installation with UPS.
12 Get it approval by your instructor.

8 Connect the battery to UPS as in Fig 1.

9 Complete the connection of UPS with loads for one
room as in Fig 1.
__________
TASK 3: Wiring for OFF line UPS to single and two rooms
1 Read and interpret the name plate details of OFF line
UPS.
2 Note down in Table 2.
Table 2
Model __________________
Type __________________
Paner rating __________________
Input and output voltage __________________
Battery rating __________________

3 Identify the input and output terminals of OFF line UPS.

(for one room)
4 Connect the incoming supply to main double pole
switch (DP) input terminals. (Fig 3)
5 Connect outout of DP to input of UPS terminals. 10 Repeat the at one 8 km steps (3 to 9) and complete
6 Connect the output live (phase) terminal only of UPS the OFF line UPS wiring for 2 room as in Fig 4.
to the incoming of switch (SW1).
7 Take neutral connection from the output of main DP
switch.
Do not take neutral from output neutral
terminal of UPS. Neutral connection is taken
directly from supply mains only.
8 Connect the phase connection of each loads through
switches and neutral from socket and lets as in Fig 3.
9 Complete the wiring for one room as in Fig 3.

274 Power: Wireman (NSQF Level - 4) Exercise 1.15.94

11 Test the completed wiring installation.
12 Get it approved by your instructor.
Caution: Do not connect an off-line and an
online through a changeover circuit, because
output wiring of two are different. In off-line
input and output neutral are common. In online
inlut and output have different neutrals. Higher
capacity on line systems are using 60A
connector for inputs and outputs higher
capacity on line systems (above 5 KVA) are
going for three phase on-line systems.
__________
TASK 4: Wiring installation for 3 phase OFF line UPS for office building
1 Collect the connected load required details of the office Table 3
building for the selection of 3 phase UPS.
Type of UPS _____________OH/OFF line
2 Select the correct capacity of 3 phase UPS unit by
considency the following points. Supply _____________ 3 phase/single phase
• List all the equipment to be protected by the each Model __________________
phase of 3 phase UPS. Mode __________________ 3/3 or 3/1
Consider if the connected loads are connected Power rating __________________KVA
3 single phase simply select 3/1 mode UPS.
(Input is 3 phase and output in single phase Battery rating __________________
supply). If the loads are connected in 3 phase Back up fire __________________
3 wire system, then select 3/3 mode UPS (V)
Input in 3 phase output also in 3 phase supply. 6 Identify the input and output terminals of 3 phase UPS.
• Calculate the VAO capacity of each device and 7 Connect the output terminals of MCCB main switch of
obtain the total VA capacity of the connected load. each phase terminals (RYB) to the cares pending phase
• Add 10 to 20% of total connected load for future input terminals of UPS (RYB) as in Fig 5.
extension.
8 Connect the each phase output terminals (RYB) of UPS
2 Select the size of the cable based on the maximum to the corresponding sub circuit distribution copper and
load connect of each phase. bar of each phase (RYB) as in Fig 5.
3 Select the best location and disign the space for the
Connect the red colour cable to red phase and
selected 3 phase UPS system prior to twisted.
similarly for yellow and blue phases.
Wiring for 3 phase UPS for OFF line 3 rooms
9 Take separate neutral lines for each phase as in Fig 5.
office buidling.
10 Complete the wiring installation of UPS for the office
4 Read and interpret the name plate details of the given
building.
OFF line 3 phase UPS.
11 Test the completed UPS using installation for its
5 Record the details in Table 3.
function.
Fig 5

__________
Power: Wireman (NSQF Level - 4) Exercise 1.15.94 275
Power Exercise 1.15.95
Wireman - Commercial Wiring

Testing of Industrial wiring and UPS wiring installation

Objectives: At the end of this exercise you shall be able to
• test and identify the problems in u.p.s
• rectify the identified problem by referring trouble shooting block diagram
• replace the recharged battery.

Requirements
Tools and Instruments Equipments/Machinery
• Trainees tool kit - 1 Set. • Common UPS 625 VA/12 V - 1 No.
• Connector screw driver set - 1 Set. • Sealed lead with operation manual
• Line/Neon tester 500 V - 1 No. battery (maintenance free battery) - 1 No.
• Soldering iron 35 W/250V - 1 No. 12V/120AH
• Desoldering gun - 1 No.
Materials
• Multimeter (analog (or) digital) - 1 No.
• Clamp on meter - 1 No. • Spare components - as reqd.
• Solder 60/40 - as reqd.
• Soldering flux - as reqd.
• Connecting wires - as reqd.

PROCEDURE
TASK 1: Test and identify the faults and rectify in UPS

1 Read and interpret the name plate details of the given 6 If the U.P.S is not off, then check the condition of
U.P.S. switch, (or) back up LED (yellow Led) (or) press the
switch for more than 3 seconds and rectify the problem,
Type of U.P.S ............................. ON line/OFF line
if the U.P.S not switched off.
Model .................................................................
To de-energise the U.P.S properly in
Power rating ..................................................VA emergency, the right way is to switch 'off' the
Change over time ..................................... m sec I/O switch to 'OFF' position and disconnect the
power cord from the main supply.
Battery rating ......................................................
7 Press the ON/OFF/test/silence switch, more than 3
Back up time .......................................... Hours seconds; to switch off the U.P.S and battery.
2 Switch 'ON' the U.P.S, with U.P.S. 'Plugged in' 8 Observe the back up yellow LED.
3 Press and hold ON/OFF /test/silence button for more If the yellow LED (Back up) lights 'off' , the ups
than one second until "Line normal" LED green lights and battery is on 'OFF' position. If the back LED
up. (i.e U.P.S. 'ON' and ready for use.) is not 'off', it indicates U.P.S always at battery
If green LED does not light up, the possible mode. The causes for this fault may in power
causes may be (i) button not pressed (or) cord, fuse or power normal voltage.
pressed to short (ii) voltage of battery less than 9 Check the condition of power cord, A.C fuse, up normal
10V (iii) PCB -failure and (iv) load may be less voltage and PCB.
than 20W at battery mode.
10 Rectify problem by referring the trouble shooting
4 Identified the problem by self testing U.P.S., and rectify sequence block diagram (Fig 2).
this fault by referring the trouble shoot sequence block
diagram (Fig 1).
5 Switch OFF the ups press and hold the ON/OFF /test
silence button for more than 3 seconds until the "Line
normal" or "back up" LED off.

276
Power: Wireman (NSQF Level - 4) Exercise 1.15.95 277
11 Press the ON/OFF/test silence button less than one
second, when A.C mains supply is available observe
the operation U.P.S.
If the U.P.S briefly operates the loads on battery
and the on battery LED lights up, it indicates
U.P.S is in on line operation.
If the U.P.S does not operate the loads on
battery mode and immediately returns to on
line operation and lights up the RED0-LED, it
indicates that the back up time is too short the
battery is to be replaced (or) to be recharged
(it back up wire time is too short).
12 Recharge the battery immediately for atleast four hours.
13 Check and test u.p.s with recharged battery and rectify
the fault by referring Fig 3. Trouble shooting sequence If it is stopped in back up mode it indicates
block diagram. U.P.S is in normal. But, if the beep sound
If the "replace battery" (Red LED) is still on, alarms continuosly, It indicates that U.P.S in
replace the battery. over loaded.
14 Press the on/off/test/silence button for less than 1 sec 16 Press the button (on/off) during alarams to stop the
in 'Back up' mode, observe the audible alarm, It should beeping when yellow LED (Back up) lights up.
be 'silence'. 17 Check for the maximum connected load to UPS and
If does not function under 'Low battery (or) over rectify this fault by disconnect the excess until the
load conditions. beep alaram is not available.
15 Observe the beeping alaram, when pressing the silence
button to stop the operation of U.P.S.
__________

TASK 2: Replacement of Battery

Follow theninstruction end procedure below for easy 8 Remove the battery from the unit easily.
battery replacement.
Cautions:
1 Unplug unit from A.C. power source and disconnect all
• Do not dispose of batter in fire.
connected equipments /load.
• Do not attempt to open the battery.
2 Disconnect A.C. power cord from U.P.S unit.
• Use tools with insulated handles.
3 Turn the unit upside down and unscrew the 4 screws
on top of the battery. • Remove watches rings etc while charging
the battery.
4 Keep the screws in a safe place for re assembling.
9 Place your new battery in the same position (or)
5 Turn the entire unit right side up, by holding the top
direction as the old one.
firmly.
10 Reconnect the leads (i.e) Read load to positive (+ve)
6 Lift top cover off and place ti the side.
position and black lead negative (-ve) position.
The connection and electronics components
11 Reconnect your equipment properly by following the
will be exposed. Do not touch an innder
steps 6,5 and 3 (in that order).
components when changing the battery.
12 Check the unit for its good condition and performance.
7 Disconnect and remove the two leads (Rod & black)
from the battery.

__________

278 Power: Wireman (NSQF Level - 4) Exercise 1.15.95

Power Exercise 1.15.96
Wireman - Commercial Wiring

Straight and cross crimping of RJ-45 cable

Objectives: At the end of this exercise you shall be able to
• make straight crimping of RJ45 cable by using crimping tool
• make cross crimping of RJ45 cable by using crimping tool.

Requirements
Tools and Instruments/equipment Materials
• RJ45 cable crimping tool - 1 No. • RJ45 cable - as reqd.
• Insulated combination pliers 200mm - 1 No. • PVC end clips T568A & T568B - as reqd.

PROCEDURE
TASK 1: Make straight crimping of RJ45 cable by using crimping tool
1 Inspect and fix the place / position where the computer 6 After completing of this straight crimping connect to
and telephone are to be placed. computer and telephone /WAN/ port.
2 Plan to connect one computer and one telephone
initially. Sl.No. T-568B (Common) T-568A
3 Make a estimate on to the total length of RJ 45 cable 1 Orange stripe Green stripe
required for installation from the exit points of telephone 2 Orange Green
line.
3 Green stripe Orange stripe
4 Insert the cable through the existing wiring channels
already made. 4 Blue Blue

5 Terminate the cable end of the PVC end clips pin 1 to 5 Blue stripe Blue stripe
1, 2 to 2 and 3 to 3 etc as shown in Fig 1. 6 Green Orange
Fig 1 7 Brown stripe Brown stripe
8 Brown Brown

__________
TASK 2: Make cross crimping of RJ 45 cable by using crimping tool

There are two types of network cables Pin - 7 - Pin 7

commonly used in P.C. networks. Straight Pin - 8 - Pin 8
through and cross over.
RJ45 to RJ45 cable pinouts
Straight Connection
Straight through cable T568B
Pin - 1 - Pin 1
RJ45 Connects to RJ45
Pin - 2 - Pin 2
Pin No. Pin No.
Pin - 3 - Pin 3
1 Orange stripe 1
Pin - 4 - Pin 4
2 Orange 2
Pin - 5 - Pin 5
3 Green stripe 3
Pin - 6 - Pin 6
4 Blue 4

279
 5 Blue stripe 5 Crossover Cable T568B
6 Green 6 RJ45 Connects to RJ45
Pin No. Pin No.
7 Brown stripe 7
8 Brown 8 1 3

T5684 Crossover connection 2 6

Pin - 1 - Pin 1
3 1
Pin - 2 - Pin 2
Pin - 3 - Pin 3 4 7

Pin - 4 - Pin 4 5 8
Pin - 5 - Pin 5
6 2
Pin - 6 - Pin 6
Pin - 7 - Pin 7 7 4
Pin - 8 - Pin 8
8 5

Hub Switch Router Work station

Hub Crossover Crossover Straight Straight

Switch Crossover Crossover Straight Straight

Router Straight Straight Crossover Crossover

Work station Straight Straight Crossover Crossover

1 Plan to connect through RJ 45 cable from a router to T568A Crossover connection

router and router to work station.
Pin - 1 - Pin 3 White orange 1
2 Lay both the cable through the existing wiring channel
Pin - 2 - Pin 6 Orange 2
already made.
Pin - 3 - Pin 1 White green 3
Pin - 4 - Pin 7 Blue 4
Pin - 5 - Pin 8 White Blue 5
Pin - 6 - Pin 2 Green 6
Pin - 7 - Pin 4 White & Brown 7
Pin - 8 - Pin 5 Brown 8

3 Terminate one cable ends to PVC end clips T568A

1 to 3, 2 to 6, 3 to 1, 4 to 4, 5 to 5, 6 to 2, 7 to 7 and
8 to 8.
4 Terminate another cable ends to PVC end clips T568B,
1 to 3, 2 to 6, 3 to 1, 4 to 7, 5 to 8, 6 to 2, 7 to 4 and
8 to 5.
Commonly T568B connection is used for cross
over connection.

280 Power: Wireman (NSQF Level - 4) Exercise 1.15.96

Pin Number Designations
There are pin number designations for each color in
T-568B and T-568A
T568B T568A
Pin Color Pin Name Color Pin Name
1 Orange TX+ Green RX+
stripe stripe
2 Orange TX- Green RX-
3 Green RX+ Orange TX+
stripe stripe
4 Blue Not used Blue Not used
5 Blue Not used Blue Not used
stripe stripe
T568B Straight Connection
6 Green RX- Orange TX-
1 ====================== White & Orange
7 Brown Not used Brown Not used
2 ====================== Orange
stripe stripe
3 ====================== White and Green
8 Brown Not used Brown Not used
4 ====================== Blue
5 ====================== White and Blue
5 Insert RJ45 jack in to crimping plier and connect
between router to work station. 6 ====================== Green
T568A Straight Connection 7 ====================== White and Brown
1 ====================== White & Green 8 ====================== Brown
2 ====================== Green T568A Crossover Connection
3 ====================== White and Orange 1 ====================== White & Orange
4 ====================== Blue 2 ====================== Orange
5 ====================== White and Blue 3 ====================== White and Green
6 ====================== Orange 4 ====================== White and Brown
7 ====================== White and Brown 5 ====================== Brown
8 ====================== Brown 6 ====================== Green
7 ====================== Blue
8 ====================== White and Blue

Power: Wireman (NSQF Level - 4) Exercise 1.15.96 281

TASK 3: Make the termination of RJ 45 cable, by using crimping tool
1 Trim the end of the cable terminating, by using a If not remove them from the connector. rear-
crimping tool. range into proper formation, and re-insert.
Ensure that the ends of the conducting wires Remember, once the connector is crimped onto
are even. the cable, it's permanent. If you realize that a
mistake has been made in wire order after
2 Strip off approximately 1 inch of the cable jacket. termination, you'll have to cut the connector
Fig 1. off and start al over again!
Careful not to damage the inner conducting 8 Insert the prepared connector/cable assembly into the
wires. RJ45 slit in your crimping tool. (Fig 5)
3 Un wind and pair the similar for T568B connection colour Firmly squeeze the crimper's handles together
separate the 4 twisted wie pairs from each other, and until you can't go any further. Release the
then unwind each pair, so that it will end up with 8 handles.
individual wires. (Fig 2)
9 Repeat this step to ensure a proper crimp. Remove
Flatten the wires out as much as possible, the cable from the crimper that end is ready to use.
using sensor since they'll need to be very
straight for proper insertion into the connector. If your crimper doesn't automatically trim the
(Fig 3) wire ends upon termination, carefully cut wire
ends to make them as flush with the
4 Hold the cable with the wire ends facing away from connector's surface as possible. The closer the
you moving from left to right, arrange the wires in a flat. wire ends are trimmed, the better your final
Side-by-side ribbon formation, placing them in the plug-in connection will be.
following order; white/orange, solid orange, white/green,
solid blue, white/blue, solid green, white/brown, solid 10 Moving from left same colour order on the plier end to
brown. right arranged the wires side by side ribbon formation
placing them according to crossover connection given
5 Hold the RJ45 connector so that its pinsa are facing in the Fig.
away from you and the plug-clip side facing down,
carefully insert the flattened, arranged wires into the 11 Repeat proccess on the opposite end of your cable
connector. (Fig 4) also. Repeat process on the other end of the cable.

6 Push through until the wire ends emerge from the pins. For a standard "Straight through" cable repeat
all steps and wire colour order at other end of
For strength of connection, also push as much cable. For a cross over cable the other end
of the cable jacket as possible into the have different colour wires.
connector.
7 Check to make sure that the wire ends coming out of
the connector's pin side are in the correct order.

__________

282 Power: Wireman (NSQF Level - 4) Exercise 1.15.96

Power Exercise 1.15.97
Wireman - Commercial Wiring

Crimping of co-axial cable, proper installation of co-axial cable from dish antenna
to Television set
Objectives: At the end of this exercise you shall be able to
• practice on crimping of coaxial cable
• install the RJ45 coaxial cable for DTH termination to TV
• make the termination of RJ 45 cable, by using crimping tool.

Requirements
Tools and Instruments/equipment Materials
• Multi purpose crimping tool - 1 No. • RJ45 Coaxial cable - as reqd.
• Insulated combination pliers 200mm - 1 No. • Video RF cable - as reqd.
• Electrician knife 100 mm - 1 No. • Cable connector plug - 1 No.

PROCEDURE
TASK 1: Practice on crimping of coaxial cable

1 Collect the required length of coaxial cable. (Fig 1) Do not apply any force which may cause for
2 Cut the end of the cable using small sharp wire cutter. the damage of insualtion.

3 Create a squared off surface and mould the ends of 6 Pull off the material gently using fasten after mainly 2
coaxial cable using fingers. cuts, and remove the outer insulation (layer of fault)
have conductor will expose.
4 Insert the coaxial cable into loan shipper tool. (Fig 1)
7 Tear of the exposed foil (metal wash) under the metal
Fig 1 mesh left around the inner insulation.
8 Bend the mesh all the way back so that it is molded
over the end of the outer insulation.
9 Press the end of the coax into the back of an 'F'
connector.
Use straight pressure only do not twist the coax
in line body of the connector.
10 Place the 'F' connector into the coax crimping tool,
and squeeze fully the tool handle and release.
11 Remove the finished crimp connection from the tool.
Make sure that the end of the coaxial cable is
flush against wall or guide on the tool. 12 Show the crimped coaxial cable to your instructor for
approval.
5 Spin the tool around the coaxial 4 or 5 times (or) until,
lear no sound of the metal scaring.
__________

TASK 2: Install DTH to television using coaxial cable

1 Select the location and position of DTH termination 4 Install a copper wire (#10) between home grand point.
end to TV.
Use spread clamp desigrad for this purpose to
2 Prepare an estimate to install DTH to TV and measure connect the # 10 wire to the house ground pant.
the length of coaxial cable required. (Fig 1) Leave enough ground wire to the end through
each ground block terminal.
3 Install a ground block in convenient location any where
between the dish and prior entering the game.

283
Fig 1 15 Switch 'OX' the supply and change the channels to
test both turners for TV and DVR.
Use recievers set up box to view signal strength
of each satilite and turner.
16 Inspect the DTH termination end to lay the co-axial to
TV.
17 Make an estimation to the total length required to
connect DTH to TV.
18 Lay the co-axial cable from DTH end to TV point through
the channles already existing.
5 Rotate the cable and secure with stapler to the 19 Connect the cable connector plug to the co-axial cable
mounting surface and tighten the grand terminal screw end.
to the ground wire.
20 Test the wiring installation for its working condition.
6 Lay, coax cables from each of the dishes output
Do not tie RJ45 cable, co-axial cable together
terminal into due ground block.
with supply line & wires.
7 Run a cable from any roof top antenna to the side of
ground block. Coaxial Crimping Tool
8 Run the same number a cables into the ground black RG59/6 Coaxial Ratchet Crimping Tool
between ground block and control location.
SKU # 2501-SF-11
9 Run cables from each turner to the central location.
RF59/6 Ratchet Crimping Tool. RG58 / 59 / 62/ 6 Belden
10 Select a multi switch Fig 2 to determine number of 8279.8.1mm (0.319 inches); 6.5mm (0.256 inches);
inputs and outputs required. 5.41mm (0.213 inches); 1.72mm (0.068 inches)

Fig 2

The number of outputs of the multi switch Crimp Tool for stripping cable RG58-RG59-RG62
equals to the number of turner not the number SKU # 68TL-A1
of set top boxes. Multi switch must have extra
outputs to unconditional recerien. For stripping RG cable: RG-58/59/62/6/6QS/3C/
4C/5C. Manufacturer No: HT-332. Stripping
11 Install the multi switch and connect the dish coaxial Length: This stripper can strip cable in four
cables to the dish input connector and the antenna. lengths 4;6;8 and 12mm/ The stripping length
12 Check connection and hardware until satisfied. is preset to 6mm. Strip other lengths; adjust
the balde's position.
13 Connect the coaxial cable from the receivers to the
multi switch output connection.
14 Connect coaxial cables to each turner input at the
receiver end.

284 Power: Wireman (NSQF Level - 4) Exercise 1.15.97

Power Exercise 1.16.98
Wireman - Industrial Wiring - II

Installations Industrial wiring for mixed load, both light and power
Objectives: At the end of this exercise you shall be able to
• prepare layout diagram of industrial wiring for power and light load
• list out the materials required
• select the cable according to load
• connect distribute load evenly in all phases
• bus bar and mains
• connect service main cable and test it.

Requirements
Tools and Instruments/equipment • Fuse unit flush type 250V/6A - 3 Nos.
• Neon indicator with holder panel type - 3 Nos.
• Wireman tool kit - 1 No.
• SP switch 250V/6A (flush type) - 3 Nos.
• Electrician drilling m/c 12mm - 1 No.
• 14 SWG metal conduit pipe 25mm - 20 length.
• Drill bit 4mm - 1 No.
• Metal conduit accessories bend,
• Drill bit 6mm - 1 No.
elbow, coupling, function boxes - 20 Nos
• Megger 500V - 1 No.
each
• M.I. Voltmeter 0-600V panel type - 1 No.
• Earth clamp 25mm - 100 Nos.
• MI Ammeter 0-30A - 1 No.
• G.I. earth wire No 10 SWG - 20 m.
• Hand crimping tool - 1 No.
• Wood screws assorted size - as reqd.
• Scriper - 1 No.
• G.I. conduit saddles - 300 Nos.
• Centre punch - 1 No.
• Wooden plugs - 500 Nos.
Materials
• Metal flexible conduit - 50 m.
• ICTP switch with neutrally link • Metal flexible conduit 25mm coupling - 20 Nos.
415/400A - 1 No. • Metal flexible conduity coupling
• 200A bus bar champer with metal box - 1 Set. check nut - 20 Nos.
• ICTP switch with neutral link • 1.5 sqmm PVC copper wire 600V - 200 m.
415V/63A - 1 No. • 2.5 sqmm PVC copper wire 1100V - 300 m.
• ICTP switch with neutral link • 4 sqmm PVC copper wire 1100V - 50 m.
415V/32A - 1 No. • 25 sqmm UG cable 3 ½ core - 20 m.
• Power distribution box 415V/32A 12 way- 1 No. • Cable gland suitable for 25 sqmm - 2 Nos.
• Power distribution box 415V/16A 8 way - 1 No. • Cable trunking metal box - 1 No.
• Lighting distribution box 250V/16A • Metal frame will stand for fixing
6 way - 1 No. 400A main, bus bar champer,
• Rotary switch for voltmeter 415/6A - 1 No. submain and DB - 1 Set.
• Rotary switch for ammeter 415V/6A - 1 No. • Bolt and nut with washer - as reqd.
• Lighting distribution box 250V/16A
12 way - 1 No.
• Four pole MCB with metal box
415V/16A - 1 No.

PROCEDURE
1 Draw the layout diagram. Provide bus duct between mains and bus bar
2 Collect all the materials required for this exercise and to restrict insects entry.
check it. 7 Assemble the Voltmeter, Ammeter, fuses switch and
3 Fix the main frame rigidly in your section. rotary switch in teh metal box given connections and
fix it.
4 Mark the fixing holes for main switch, bus bar champer,
sub mains and distribution box. 8 Measure the length between sub mains (S1, S2, S3 &
S4) and DB (PDB1, PDB2, LDB1, LDB2) cut the conduit
5 Punch and drill holes. and fix it.
6 Fix main switch, bus bar champer, sub mains and DB 9 Inter connect mains, bus bar, submains DB and meter
one by one. Fig 1. box by 4 sqmm PVC copper wire.

285
 Use lug, sockets and the mains for termination. 19 Cut, thread and prepare the conduit for fixing.

10 Measure the length of UG cable from main source. 20 Measure the length of cable for connecting all power
loads and make pieces according to it.
11 Lay the cable properly, either by lemping in the wall
(or) in the duct. Use 2.5 sqmm PVC copper wire for power loads.

Avoid running the cable ON the open floor. 21 Complete the connections.

12 Terminate both ends by cable gland and sockets. 22 Repeat the steps 18 to 21, to connect all lighting loads.

13 Connect the cable on both ends. Use 1.5 sqmm PVC copper wire for lighting
loads.
First connect the cable in the newly fixed panel
(Non supply side). 23 Test all the connections of wring using megger.

14 Give earth connection to all metallic parts. For lighting load provide are earth for complete
circuit.
For power wiring double eathing is necessary.
24 Re fix all the fuse carriers.
15 Check, insulation resistance and continuity by megger
before swith on the supply. Use proper rating of fuses.

16 Switch ON the supply and test with test with test lamp. 25 Before switch ON supply inform to your instructor.

Use low rating fuse wire (testing fuse). 26 Switch 'ON' the power supply and test the working.

17 Switch OFF the supply and remove all the fuses.

18 Measure the length of conduit to connect all power
loads from PDB1 & PDB2.
__________

286 Power: Wireman (NSQF Level - 4) Exercise 1.16.98

Power Exercise 1.16.99
Wireman - Industrial Wiring - II

Layout of L.V. AC/DC machines and their panels

Objectives: At the end of this exercise you shall be able to
• prepare layout diagram for LV, AC/DC machine
• draw layout diagram for panel.

Requirements
Tools and Instruments/equipment Materials
• Steel rule 300 mm - 1 No. • A4 Sheet - 1 No.
• Pencil - 1 No.

PROCEDURE
1 Read and interpret the name plate details of motor and 3 Consult with your instructor for the requirements of the
D.C. generator. panel board for AC motor and DC generator and location
of each.
2 Estimate the rated materials, instruments and switches
required. 4 Draw the layout diagram. (Fig 1)
5 Show it to your instructor and get it approved.

__________
287
Power Exercise 1.16.100
Wireman - Industrial Wiring - II

Wiring of Low power A.C./ D.C. machines in metal conduit system as per I.E.
Rules
Objectives: At the end of this exercise you shall be able to
• read and record the name -plate details of the MG set
• prepare the list of accessories to be installed on the panel
• draw the layout of the panel and fix the electrical accessories
• wire up the panel
• install the conduit runs from the MG set to the panel and wire up
• earth the MG set panel and the conduit runs
• test the installation for continuity, insulation and earth continuity
• test the installation (with supply) by energising.

Requirements
Tools and Instruments • Field regulator toriidal type 415V,
2 amp 300 phm - 1 No.
• Wireman tool kit - 1 No.
• Ammeter MC 0-2 amp - 1 No.
• Hacksaw 300 mm - 1 No.
• Star Delta starter 500 Volt, 6-10 amp - 1 No.
• Measuring steel tape 5m - 1 No.
• Ammeter MI 0 to 15 amp - 1 No.
• Portable electric power drilling
• Voltmeter MI 0 to 500 V - 1 No.
machine 12 mm capacity - 1 No.
• DE spanner set 8-22 mm - 1 Set. Materials
• Adjustable spanner 300 mm - 1 No.
• Kit-kat fuse 240V, 6 amp - 3 Nos.
• HSS drill bit 6 mm to 12 mm - 1 Set.
• ICTP switch 415V 32 amp - 1 No.
• Bench vice 100 mm jaw - 1 No.
• ICDP 240V, 16 amp - 1 No.
• Test lamp 60 W, 240V - 1 No.
• Bakelite, batten holder 6 amp 240V - 4 Nos.
• Megger 500 V - 1 No.
• Kit-kat fuse 240V, 16 amp - 2 Nos.
• Earth tester - 1 No.
• SPT switch 240V 6 amp - 4 Nos.
Equipment/Machines
• Colour bulbs 240V, 15V, 15W red, yellow - 1 each.
• Motor -generator set 220V, 3 kW blue green
1450 rpm. Coupled with A.C. induction • PVC copper cable 2.5 sqmm 1100V - as reqd.
motor 3.5 kW, 415V 50 Hz - 1 Set. • PVC copper cable 1.5 sqmm - as reqd.
• Voltmeter MC 0-300 V - 1 No. • Brass nut-bolts M3x50mm for 600V - 25 Nos.
• Ammeter MC 0-20 amps - 1 No. • HDBC/G.I. wire 10 SWG for earthing - 10 m.
• Change over rotary switch 500V - 1 No. • Fuse wire 30 amps capacity - as reqd.
• Hacksaw blade 300 mm 18 TPI - 6 Nos.

PROCEDURE
TASK 1: Preparation of layout for MG set panel board

1 Read and interpret the name-plate details of the motor Rating Connection Insu. Class
and generator set and record them in Tables 1 and 2.
________ ________ ________
Table 1
Name plate details of the motor 2 Estimate the components required for the MG set panel
board and accordingly draw the schematic diagram of
Make Frame No Model connection of the MG set panel board with the required
________ ________ ________ switches, indicators, regulators and instriments in your
record.
Phase Kilowatt/H.P r.p.m PF
3 Show the scematic diagram to your instructor for
________ ________ ________ ________ approval. (Schematic diagram Fig 1)
Volts Amperes Frequency 4 Collect all the required accessories and verify it.
________ ________ ________

288
 Table 2 5 Assemble the panel board accessories and
Name -plate details of the generator instruments.

Manufacturer, trade mark _____________________ 6 Wire up the panel board as per wiring diagram. (Fig 2)
Type, model or list number _____________________ Wiring must be done by 1.5 sqmm PVC copper
wire.
Type of current _____________________
Function _____________________ 7 Fix th panel board near to motor generator set.

Generator/motor _____________________ 8 Measure, cut and thread the conduit as per dimension.
Fabrication or serial number _____________________ 9 Measure and cut the required size of cable.
Type of connection _____________________ 10 Fix the conduit and wire up the panel board with M.G.
sep/shunt/series/compound set. (Fig 2)

Rated voltage _________________Volts Use 2.5 sqmm PVC copper wire M.G. set and
panel connection.
Rated current _________________amps
11 Test the continuity and insulation resistance by megger.
Rated power _________________K.W.
Rated speed ________________r.p.m. Double earthing must be done for power wiring.

Rated exc. voltage ___________________ V 12 Switch ON the power supply and start the M.G. set.
Rated exc. current _________________amps Check the D.O.R. of induction motor. If it is in
anti clock wise direction change the D.O.R by
Rating class _____________________
inter changing and two phases.
Direction of rotation _____________________
13 Very the DC generator field excitation upto rated output
Insulation class _____________________ voltage.
Protection class _____________________ 14 Switch on the load and check the function of ammeter.

__________
Power: Wireman (NSQF Level - 4) Exercise 1.16.100 289
Power Exercise 1.16.101
Wireman - Industrial Wiring - II

Testing of 3 phase power wiring installation

Objectives: At the end of this exercise you shall be able to
• test the insulation resistance value between phases 3 phase wiring installation
• test the insulation resistance value between phase and earth.

Requirements
Tools and Instruments/equipment Materials
• Wireman tool kit - 1 Set. • Connecting leads - as reqd.
• Megger 1000V - 1 No.
• Test lamp (dual) - 1 No.

PROCEDURE
TASK 1: Test the insulation resistance value between phases of 3 phase wiring installation
1 Select power distribution board for testing.
2 Switch OFF the main and remove all the fuse carriers
in the main and sub main.
3 Get a megger from your instructor and check its
condition.
For power wiring 1000V range megger must
be used to get occurate result.
4 Check the IR value between R phase and 'Y' phase
(Fig 1) and note down the reading in Table 1.
5 Repeat the checking between Y phase and B phase
and B phase and R phase and note down the readings.
IR value between phase to phase must be more
than one mega ohm.
Megger must not be used on live line.
Table 1
I.R. Value between Phases
Sl.No. Terminal I.R. Value in M
1 R and Y
2 Y and B
3 B and R
__________
TASK 2: Test the insulation resistance value between phase and earth
1 Check IR value between R phase and Earth. IR value between phase and earth should not
2 Note down the radings in Table 2. be less than and mega ohm.

3 Repeat the checking between Y phase and Earth, B Table 2

phase and earth. I.R. Value between Phases and Earth
4 Note down the readings in Table 2. Sl.No. Terminal Value in M
5 Disconnect the megger leads and keep it safely. 1 R and Earth
6 Show the readings to your instructor and get it 2 Y and Earth
approved.
3 B and Earth
__________
290
Power Exercise 1.16.102
Wireman - Industrial Wiring - II

Wiring of different circuit using Single core cable use for 2 ways, intermediate
master switches etc
Objectives: At the end of this exercise you shall be able to
• draw the layout and connection diagram of corridor wiring
• draw the layout connection diagram of for one lamp controlled from three different places with master switch
• draw the layout and connection diagram for one lamp controlled from five different places
• estimate the materials required
• prepare the conduit for wiring
• fix the conduit with accessories
• draw the cable, fix and connect the accessories
• test the wiring.

Requirements
Tools and Instruments/equipment • Conduit pipe inspection Tee 25mm - 3 Nos.
• Conduit elbow 25 mm - 4 Nos.
• Wireman tool kit - 1 No.
• Conduit bend 25 mm - 1 No.
• Conduit die set with 25mm dies
• Conduit junction box 3-way 25mm - 4 Nos.
and collet - 1 Set.
• T.W. spacers 60mm long 19 mm wide
• Metre scale 300mm - 1 Set.
and 12mm thick - 25 Nos.
• Oilcan with coconut oil - 1 No.
• Tinned copper wire SWG - 12 mts.
• Reamer, suitable for 25mm dia
• Earth clamps, tinned copper suitable for
conduit pipe - 1 No.
25mm pipe with bolt, nut and washers - 3 doz.
• Round file bastard 200mm - 1 No.
• G.I. saddles 25 mm - 25 Nos.
• Flat file bastard 200mm - 1 No.
• Wood screws and machine screws
• Pipe vice, suitable for 25mm pipe
assorted - as reqd.
with stand - 1 No.
• P.V.C. copper cable 1.5 sqmm 250V grade - 18 mts.
• Cleaning brush - 1 No.
• S.P. switch 6A 250V (Flush type) - 1 No.
• Plump bob with thread - 1 No.
• Two-way switch 6A 250V - 6 Nos.
• Poker 200mm - 1 No.
• Ceiling rose 2-way 6A 250V - 4 Nos.
• Hand drilling machine 6mm capacity
• Intermediate switch 6A 250V - 4 Nos.
with 4mm drill bit - 1 Set.
• Pendent-holder, bakelite 6A 250V - 4 Nos.
• Scriber 200mm - 1 No.
• B.C. bulbs 40W, 230V - 4 Nos.
• Megger 1000V - 1 No.
• Colour chalk - 1 piece.
• Rawl jumper No 14 - 1 No.
• Terminal plate 16 amps 3-way - 1 No.
Materials • G.I. wire as fish wire 14 SWG - 6 mts.
• P.V.C. bushes suitable for 25mm pipe - 40 Nos.
• Coduit pipe, heavy gauge 25mm dia - 5.5 M.
• Conduit check-nut 25mm - 8 Nos.
• Conduitn one-way juntion box 25mm - 4 Nos.
• Metal box 90mm square or hexagonal
type with top cover - 4 Nos.

PROCEDURE
TASK 1: Wire up a corridor for the given layout

1 Form the circuit with the required wiring accessories 2 Get the circuit approved by the instructor.
as per the circuit diagram (Fig 1) on the workbench.
If it is incorrect, trace the circuit and correct it.
3 Mark the layout on the I P C as per the given layout in
Fig 2.
4 Select the required conduit fittings as per layout.
5 Measure the length of conduit pipes cut and thread it.

291
 Battern holders can be fitted directly on the
one-way junction boxes using the machine
screws provided for fixing the cover.
10 Prepare the cable ends and terminate them in the
accessories and fix the accessories.
11 Clise the top covers on the metal boxes.
12 Close the inspection windows of the inspection type
accessories.
13 Run the given earth wire along the conduit pipe by
means of earth clamps and terminate at the junction
boxes and metal boxes. (Fig 4)
It is necessary to follow the looping system to
6 Prepare the T W spacers with through holes for fixing avoid joints in the earth wire runs or use
on the I P C and the pilot holes to fix the saddles. bonding of earth wire.
7 Fix the T W spacers as per layout. Remove the paint on the surface of the conduit
and then fix the copper earth clamps.
8 Fix the conduit pipe and conduit accessories as per
the layout by means of saddles. 14 Fix the bulbs.
Knock out holes in the square/hexagonal metal A completed installation will look as shown in
boxes for conduit pipe terminations. Fig 4.
9 Measure and cut and draw the cables. (Fig 3) 15 Get the wiring checked by the instructor.
16 Effect supply of current and test the wiring.

__________
TASK 2: Wire up one lamp controlled from 3 different places with master switches
1 Repeat the steps from 1 to 16 of Task for the following
schematic diagram. (Fig 5)
Master control switches are used to control
whole circuit.

__________
TASK 3: Wire up to control one lamp from five different places.
1 Repeat the steps from 1 to 16 of Task for the following
schematic diagram. (Fig 6)

292 Power: Wireman (NSQF Level - 4) Exercise 1.16.102

Power Exercise 1.16.103
Wireman - Industrial Wiring - II

Testing of wiring installation

Objectives: At the end of this exercise you shall be able to
• test the wiring installation for effectiveness of earth connection
• test the wiring installation for insulation (or) leakage between conductors
• test the wiring installation for insulation or leakage between conductors and earth.

Requirements
Tools and Instruments Materials
• Wireman's Hand took kit - 1 No. • Connecting prob of megger - 1 No.
• Test lamp - 1 No.
Equipment/Machines
• PVC insulated flexible cable 23/0.2mm - 10 m.
• Megger 500V - 1 No.

PROCEDURE
TASK 1: Testing for effectiveness of earth continuity

The resistance of the ECC should not exceed 1 Result: If the test lamp glows with normal
ohm whereeas the earth electrode resistance brightness this indicates there is continuity in
value should not exceed 5 ohms unless the ECC and the earth electrode resistance is
otherwise specified as per the National reasonably good.
Electrical Code. Note: As the result involves human judgement
1 With a test lamp, touch one testing prod to the earth regarding the brightness of the lamp, this test
terminal of the metal body of the DB/switch/Earth is not reliable unless otherwise supported by
terminal of the 3-pin socket and touch the other testing field experience.
prod to the phase live terminal avilable at the accessory.
2 Take necessary steps to reduce the resistance of the
ECC and the Earth electrode resistance to an accepted
value.
__________
TASK 2: Insulation resistances between conductors
1 Switch 'OFF' the main switch, remove the fuses and
the neutral link out.
2 Remove all the lamps from the lamp holders. (Fig 1)
3 Disconnect all the appliances, keep all the branch single
pole switches in the 'ON' position.
In circuits having 2-way switches, two test
readings should be taken. One switch in each
pair being changed over before taking the
second test, thus ensuring both the 2-way
switch (half) wires p and q shown in Fig 2 are
included in the test.
4 Put all the fuses back in the distribution board.
See that all the fuse wires are intact and of
proper rating.

293
5 Connect the Megger leads (E&L) to the outgoing
terminals of the main switch as in Fig 2.
6 Rotate the handle of the Megger at 160 r.p.m. Read
the insulation resistance value and enter it in Table 1.
If the Megger reading of this test is equal to or
higher than the values shown in columns 2, 3
and 4 of Table 1 or otherwise one megohm
and above, the insulation resistance of the
installation is satisfactory. If the test result is
not satisfactory follow the steps 11 to 14 given
in insulation test to earth (Task 3).

Table 1
Sl. Standard value of Calculated value of Value of ins- Measured insulation Remarks
No. insulation resistance insulation resistance ulation resistance value
as per B.I.S. rules as per IE rules resistance between
as per thumb conductors
50 Supply voltage in volts
   m
No. of points in the circuit Leakage current

in megohm in megohm rule = one in megohms

megohm or
above

__________
TASK 3: Insulation test between conductors and earth
From the insulation resistance value we can
calculate the leakage current or vice versa.
1 Put the main switch OFF. Remove the fuses of the
main switch and keep them in safe custody.
2 Insert all the fuses in the distribution board. See that
all the fuses are intact and of proper rating.
3 Insert all lamps in position. (Fig 2)
4 Close all the single pole switches 'ON'.
In an incomplete installation, the conductors
at each outlet (points and switch position) must
be joined together.
5 Short the outgoing terminals of the main switch with a
piece of wire.
care should be taken to see that the shorting
link is used in the installation side only. Service
main supply is available in the bottom portion
of the switch and any accidental contact with
the main supply would be dangerous.

294
6 Connect the 'L' terminal of the Megger to the short The measured value of insulation resistance with the
terminal of the main switch. Megger should either be equal or higher that the calculated
calculation resistance value as per IE rules.
7 Connect one lead marked 'E' of the Megger with earth
terminal of the main switch. Value as per thumb rule
Aternatively the earth connection of the However, as a thumb rule, if the measured insulation
Megger can be connected to the conduit/lead distance value is one megohm or above for the whole
sheathing/earthed water mains. installation, it is acceptable.
8 Disconnect all the domestic appliances from the some 11 If the values obtained are not sufficiently high withdraw
and short the socket before testing with the Megger. all the fuses at the distribution fuse board, disconnect
neutral, it is acceptable.
9 Rotate the handle of the Megger at 160 r p m (Apply
note the reading of the Megger). Thus this test will only include the portion of
the installation between the main switch and
In circuits having 2-way corridor switches, two
the bus-bars of the distribution board.
test readings should be taken, one switch in
each pair being changed over before taking 12 Sometimes the poor insulation resistance value may
the second test thus ensuring that both the 2- be due to the poor insulation of the cable. Then replace
way switch (half) wires are included in the test. the cable.
10 Check the readings with the following recomments 13 If the best result is found to be low still, investigate any
values. leakage between the cable and the earth at the main
switch or at the DB. Rectify the defect.
a Standard value as per BIS
If the result in procedural step 11 (Task 4) is
b Value as per IE rules
found to be OK, proceed as below.
C Value as per thumb rule
14 Insert the fuse in one circuit, connect the respective
Standard value as per BIS neutral wire to the link in the DB and repeat steps 8 to
10 (Task 4). If the reading is found to be OK, add another
50 fuse. Connect the respective neutral wire to the link in
  m the DB i.e. you are adding one more circuit, and repeat
No. of points in the circuit
steps 8 to 10 (Task 3) till you read low insulation
Where the switch and lamp holder socket are taken as resistance value. Then the circuit you added las has
individual points. low insulation resistance. Investigate the cause and
rectify the defect.
IE Rules states that leakage current in the insulation should
not exceed 1/5000th part of the full load current of the Normally the defect could be traced in ceiling
installation. roses, switches or socket connections.
15 Enter the recommended/ calculated/ measured values
Full load current of installati on in Table 2.
Leakage current 
5000 16 Remove all the shorting links in the main switch and
Calculated insulation resistance value as per IE rules. wall sockets.

Supply voltage in volts

 in m
Leakage current

295
 Table 2
Sl. Standard value of Calculated value of Value of ins- Measured insulation Remarks
No. insulation resistance insulation resistance ulation resistance value
as per B.I.S. rules as per IE rules resistance between
as per thumb conductors
50 Supply voltage in volts
   m
No. of points in the circuit Leakage current

in megohm in megohm rule = one in megohms

megohm or
above

__________

296
Power Exercise 1.17.104
Wireman - Computer Awareness

Identification of Computer Parts, Switching ON/OFF of PC, Safety Precautions

Objectives: At the end of this exercise you shall be able to
• view and identify the input and output devices connected to the computer in the lab
• disconnect the devices from the computer and reconnect them to the computer
• practice on booting the computer.
• turn OFF the computer.

Requirements
Hardware & Software
• Intel core i3 or higher with Windows 7
operating system

PROCEDURE
TASK 1: View and Identify the input and output devices of the computer
1 Identify the various devices of the computer by referring. 2 Label the identified devices with numbers.
(Fig 1)

Fig 1
1
2
5 6

3
4

9
8
7

10 12
11

295
3 Write the name of the devices in Table-1.

Table - 1

SI. No. Label Name of the Device

1 1

2 4

3 2

4 3

5 7

6 5

7 8

8 12

9 10

10 11

11 9

12 6

4 Get it checked with the instructor.

__________

TASK 2 : Disconnecting the devices from the computer and reconnecting them to the computer

Disconnecting the computer 2 Connect the mouse cable to the CPU(Central

Processing Unit) as shown in Fig 3.
1 Switch 'OFF' the power supply.
2 Unplug all the power cables(CPU, Monitor, and Printer) Fig 3
from the wall socket.
3 Unplug all the interface (data) cables from back side of
the computer.
Reconnecting the computer
Note : Check whether the data cable is PS/2 or
USB type for keyboard and mouse
1 Connect the keyboard cable to the CPU as shown in
Fig 2.
Fig 2

PS2 CABLES WITH PORT

3 Connect the monitor (interface cable) to the CPU as

shown in Fig 4.
Check the parallel cables weather male and
female pins and screw it while connecting

PS2 CABLES

296 Power: Wireman (NSQF Level - 4) Exercise 1.17.104

Fig 4 Check male and female pins of the USB or
parallel port screw it while connecting.
6 Connect the USB device to the CPU as shown in
Fig 7.
Fig 7

MALE PIN INTERFACE CABLE

4 Connect the printer power cable to the wall socket and

interface(data) cable to the CPU as shown in
Fig 5.
Fig 5 USB CABLE WITH PORT

7 Connect theCPU and monitor power cableto the wall

socket as shown in Fig 8.

Fig 8

INTERFACE CABLE WITH PORT

5 Connect the network cable to the CPU as shown in

Fig 6.
Fig 6
MALE AND FEMALE POWER CABLE

NETWORK CABLE WITH PORT

__________

Power: Wireman (NSQF Level - 4) Exercise 1.17.104 297

TASK 3 : Booting the computer
1 Switch 'ON' the power button in the CPU as shown in 2 Switch ON the power button in the Monitor as shown
Fig 9. in Fig 10.
Fig 10
Fig 9

MONITOR

3 Check and record the following status in the given

Table - 2 (with tick mark) while booting the computer.
If the above status in the Table - 1 goes wrong
recheck the connection
4 Get it checked with the instructor.

CPU

Table - 2

SI. No. Status While Booting Put a tick mark []

(if your connections are correct)

1 Beep sound been heard when a computer get started

2 Keyboard lights flashes

3 Mouse lights glows

4 Monitor lights glows (turn from yellow to green)

5 CD/DVD/Floppy drive lights flashes (turn green)

6 Power on LED and Hard disk LED glows on the CPU

(turns green)

7 Printer

a. Dot-matrix / Inkjet (The head moves from right to

left and the lights glows)

b. Laser jet (and the light glows)

__________

298 Power: Wireman (NSQF Level - 4) Exercise 1.17.104

TASK 4 : Turning OFF the computer

1 Save all of the data in the application. 3 Click start button and click shutdown button as shown
in Fig 11.
2 Close all the software's and applications.

Fig 11

4 Get it checked with your instructor.

Caution: Never connect the CPU directly on AC
mains. A power back up system (UPS) to be
used to connect the CPU. Else during power
failure, the internal parts of the CPU as well as
the data may get damaged

__________

Power: Wireman (NSQF Level - 4) Exercise 1.17.104 299

Power Exercise 1.17.105
Wireman - Computer Awareness

Identifying and using Windows, like folders, files, Editing and saving
Objectives: At the end of this exercise you shall be able to
• start with windows
• create and save a text file in wordpad
• open and edit a text file in wordpad
• copy a text file in a folder
• move and rename a file
• delete and restore a file
• create a file in paint and print.

Requirements
Tools and Instruments/equipment
• Intel core i3 or higher with Windows 7
operating system

PROCEDURE
TASK 1: Start with Windows
1 Push the computer's power button. Note: then if the monitor is not turned on, press
its power button to turn it on and wait till the
windows7 user account appears as on Fig 1

Fig 1

2 Click a user name if necessary 3 Type the password using uppercase and lowercase let-
ters as necessary, as shown in (Fig. 2).
Note: If there is only one user then there is no
need to choose a user account, go to Step 3. 4 Click the “Go” button

300
TASK 4 : Turning OFF the computer

1 Save all of the data in the application. 3 Click start button and click shutdown button as shown
in Fig 11.
2 Close all the software's and applications.

Fig 11

4 Get it checked with your instructor.

Caution: Never connect the CPU directly on AC
mains. A power back up system (UPS) to be
used to connect the CPU. Else during power
failure, the internal parts of the CPU as well as
the data may get damaged

__________

Power: Wireman (NSQF Level - 4) Exercise 1.17.104 301

Power Exercise 1.17.105
Wireman - Computer Awareness

Identifying and using Windows, like folders, files, Editing and saving
Objectives: At the end of this exercise you shall be able to
• start with windows
• create and save a text file in wordpad
• open and edit a text file in wordpad
• copy a text file in a folder
• move and rename a file
• delete and restore a file
• create a file in paint and print.

Requirements
Tools and Instruments/equipment
• Intel core i3 or higher with Windows 7
operating system

PROCEDURE
TASK 1: Start with Windows
1 Push the computer's power button. Note: then if the monitor is not turned on, press
its power button to turn it on and wait till the
windows7 user account appears as on Fig 1

Fig 1

2 Click a user name if necessary 3 Type the password using uppercase and lowercase let-
ters as necessary, as shown in (Fig. 2).
Note: If there is only one user then there is no
need to choose a user account, go to Step 3. 4 Click the “Go” button

302
Fig 2

If the password is incorrect, "The user name

or password is incorrect" message will display.
After entering correct user name and
password, the Windows 7 desktop will appear
as shown in (Fig. 3)

Fig 3

__________

Power: Wireman (NSQF Level - 4) Exercise 1.17.105 303

TASK 2: Create and Save a text file in Wordpad
1 Click the "Start button" on the “Taskbar”, point to "All
Programs" and click "Accessories", then click Fig 5
"WordPad"as shown in (Fig.4 & 5).
Fig 4

2 Type "Meeting Notes, October 11", then press [Enter]

WordPad inserts a new blank line and places
the insertion point at the beginning
3 Type "The 2013 tour will visit:", press [Enter], type "Aus-
tralia", press [Enter], type "Micronesia",press [Enter],
type "New Zealand", press [Enter], then type "Your
name"; as shown in (Fig.6).
4 Click the WordPad button on the upper-left side of the
window below the title bar, then click Save on the
WordPad menu
The first time save a file using the Save button,
the Save As dialog box opens. Use this dialog
box to name the document file and choose a
storage location for it. Under Computer, the storage locations
6 Click the Down scroll arrow in the Navigation pane scroll available on the computer, such as Local Disk
bar,as needed to see computer and any storage de- (C:) (D:) (E:).
vices listed under it 8 Click in the Filename text box to select the default
7 Click the name of the drive name Document, type Meeting, then click Save as
shown in (Fig.7)

Fig 6

304 Power: Wireman (NSQF Level - 4) Exercise 1.17.105

 Fig 7

The document is saved as a file on drive. The 9 Click the Close button on the WordPad window
WordPad program creates files using the RTF The WordPad program closes. The WordPad
format. Windows adds the .rtf file extension file saved on the hard disk drive.
automatically after you click Save.

__________

TASK 3: Open and Edit a text file in Wordpad

1 Click the WordPad button , then click Open 3 Click Meeting in the File list, then click Open
2 Scroll down in the Navigation pane and select the drive The document you created earlier opens.
The contents of Hard disc drive appear in the 4 Click to the right of the "d" in New Zealand, press [En-
File list as shown in (Fig 8). ter], then type "NIMI closed the meeting" as shown in
(Fig.9).

Power: Wireman (NSQF Level - 4) Exercise 1.17.105 305

Fig 8

Fig 9

306 Power: Wireman (NSQF Level - 4) Exercise 1.17.105

 The edited document includes the text you just WordPad saves the document with your most
typed. recent changes, using the filename and
location you specified
5 Click the WordPad button , then click Save As, as
shown in (Fig.10) 7 Click Exit

Fig 10

__________
TASK 4: Copy a text file in a folder

1 Click the "Start" button on the taskbar, then click "Com- A new folder appears in the File list, with its
puter" name, "New folder", selected. Because the
2 Double-click Hard disc drive in the file list folder name is selected, and type the text to
replace the selected text as the folder name.
3 Click the "New folder" button in the toolbar
4 Type Meeting Notes, then press [Enter] as shown in
(Fig.11).

Power: Wireman (NSQF Level - 4) Exercise 1.17.105 307

 Fig 11

5 Click the Meeting.rtf document in the File list, click

Fig 12
the Organize button on the toolbar, then click Copy, as
shown in (Fig. 12) (or) press Ctrl + C
6 Double-click the Meeting Notes folder in the File list,
the folder opens.
7 Click the Organize button on the toolbar, then click
Paste (or) Ctrl + V
A copy of Meeting.rtf file is pasted into new
Meeting Notes folder.

308 Power: Wireman (NSQF Level - 4) Exercise 1.17.105

Fig 13

__________

TASK 5: Move and Rename a file

1 Click Hard disc drive. 4 Click Documents in the Navigation Pane, under Librar-
ies.
2 Click the Meeting document to select it
6 Click the Organize button on the toolbar, then click
3 Click the Organize button on the toolbar , then click
Paste as shown in (Fig.15) (or) press Ctrl + V
Cut as shown in (Fig.14) (or) press Ctrl + X
The Meeting.rtf document appears in your
Fig 14 Documents library.

Fig 15

Power: Wireman (NSQF Level - 4) Exercise 1.17.105 309

7 Select the Meeting.rtf file , click the Organize button Fig 16
on the toolbar, then click Rename as shown in
(Fig-16).
The filename is highlighted. Just type a new
name to replace the old one, but add the word
"Notes" to the end of the filename instead.
8 Click the mouseafter the "g" in "Meeting", press
[Spacebar], then type Notes, then press [Enter] as
shown in (Fig.17).
The changed name of the document copy in
the Documents library. The filename now reads
Meeting Notes.rtf.
9 Close the window

Fig 17

__________

310 Power: Wireman (NSQF Level - 4) Exercise 1.17.105

TASK 6: Delete and Restore a file
1 Click the Start button on the taskbar, then click 4 Click the Minimize button on the window's title bar and
Documents. examine the Recycle Bin icon
Your Documents library opens. The Recycle Bin contains deleted folders and
files.
2 Click Meeting Notes.rtf to select it, click the Organize
button on the toolbar, then click Delete. 5 Double-click the Recycle Bin icon on the desktop
The delete file dialog box will display for The Recycle Bin window opens and displays
confirmation of file deletion. any previously deleted folders and files,
including theMeeting Notes.rtf file as shown in
3 Click Yes for the confirmation as shown in (Fig 18)
(Fig 19)
The deleted file was moved to Recycle Bin.
6 Click the "Meeting Notes" file to select it, then click
the "Restore this item" button on the Recycle Bin
Fig 18
toolbar
The file returns to its original location and no
longer appears in the Recycle Bin window
7 Click the Documents library in the Navigation pane
The Documents library window contains the
restored file.

Fig 19

__________

Power: Wireman (NSQF Level - 4) Exercise 1.17.105 311

Power Exercise 1.17.106
Wireman - Computer Awareness

Windows Explorer, Notepad, Paint and calculator

Objectives: At the end of this exercise you shall be able to
• create a file in MS Paint and print.

Requirements
Tools and Instruments/equipment
• Intel core i3 or higher with Windows 7
operating system

PROCEDURE
TASK 1: Create a file in MS Paint and print

1 Click the "Start button" ,Point to "All Programs", Click The Paint program window opens on the
the "Accessories" folder screen, as shown in (Fig 21).
2 Move the pointer over Paint and click once

Fig 21

3 Click the Gold button in the Colors group, move the The Select menu has several menu
pointer over the white drawing area, called the canvas, commands. The Select all command selects
then drag to draw a rectangle the entire drawing, as indicated by the dotted
4 Click the Fill with color icon in the Tools group, click line surrounding the white drawing area.
the Light turquoise color button in the Colors group. 7 Click the Rotate or flip button in the Image group, then
5 Click inside the oval, click the Purple color button, then click Rotate right 90º
clickinside the rectangle, and compare the drawing to 8 Click the Paint menu button just below the title bar,
(Fig. 22) then click “Print”
6 Click the Select list arrow in the Image group, then
click Select ‘All’.

312
Fig 22

The Print dialog box opens, as shown in 9 Click “Print”

(Fig 23). This dialog box lets as choose a printer, The drawing prints on the printer. Now close
specify which part of the document or drawing the program without saving the drawing.
to print, and choose how many copies to print.
10 Click the Paint menu button just below the title bar,
Fig 23
then click Exit, then click Don't Save as shown in
(Fig 24).
11 Get it checked with the instructor
Fig 24

__________

Power: Wireman (NSQF Level - 4) Exercise 1.17.106 313

Power Exercise 1.17.107 & 108
Wireman - Computer Awareness

Windows, explorer, Notepad, Paint and Calculator

Objectives: At the end of this exercise you shall be able to
• create a document using MS WORD 2010
• enter a text using key board
• save the file by using save and save as options
• close and open the document

Requirements
Tools and Instruments/equipment
• Intel core i3 or higher with Windows 7
operating system
• MS Office 2010.

PROCEDURE
TASK 1: Create a new document using MS WORD 2010

Fig 1
1 Press the button on the task bar, select

and click it

2 Choose MSOFFICE, select Microsoft word 2010 as

on (Fig. 1)
Note: A new Document appears on the screen
as on (Fig. 2)

314
Fig 2

__________
TASK 2 : Enter text using keyboard
1 Type the following passage in the opened new characters. Their mother died when they were
document. young. Their father places and ad for a wife in
For starting line of the paragraph “Press Tab” a newspaper. A lady named Sarah answers the
on the keyboard for indentation. ad and comes to live with the family”.
“Sarah is nice but she is from Maine and misses
“Sarah, Plain and Tall is a book by Patricia the sea. The family finds things to remind her
McLachlan. It won the Newbery medal in 1986. of her home. A hay mound is like the sand
This book is about a family that lives in the dunes. The plains stretch out like the sea. They
Midwest. Caleb and Anna are the main swim in the cow pond”.
__________

TASK 3 : Save the document using ‘Save as’ option

1 Press File, choose save option a screen appears as 3 Change the location to desktop by clicking the location
on (Fig. 3 ) bar.
2 Click save. 4 Select the folder computer literacy, and type as word
exercise 1.docx and click save button as on (Fig. 4)
A default document and library folder in C:
appears.

Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108 315

Fig 3

Fig 4

__________
316 Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108
TASK 4 : Close and open the document
1 Select file menu and click close menu item as on
Fig. 5
Fig 5

2 Open the saved file by pressing file menu and choose

the "exercise word 1" click open button as on Fig. 6

Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108 317

Fig 6

3 Type the following passage to the created file.

“But Sarah still misses Maine and decides to 4 Save it by clicking tool.
go back. Caleb and Anna are afraid she will
not return. But Sarah does come back. She
adjusts to her new life. So do Anna and Caleb
and Father. After a terrible hailstorm, they all
help repair the damage. They become a
family”.

__________

TASK 5: Create new Excel Worksheet

1. Click

All Programs

Note: Microsoft Excel 2010 splash screen ap-

pears for a moment and a new blank Excel
worksheet appears as shown in (Fig.1)

318 Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108

Fig 1

__________

TASK 6: Enter Data (Text, Number and Date) in to cells

1 Click cell A3. Type the label 'David' 12 Enter 1/1//2010 in cell C3. It displays '11-Jan' as shown
in the (Fig.2)
2 Click cell A4. Type the label 'Mary'
Fig 2
3 Click cell A5. Type the label 'Tom'
4 Click cell A6. Type the label 'Sam'
5 Click cell B2. Type the label 'Average'
6 Click cell C2. Type the label 'Date'
7 Click cell A8. Type the label 'Scientific notation sample'
Note: The Labels are left justified
8 Enter 356.60 in cell B3, it displays 356.6.
9 Enter 325.15 in cell B4
10 Enter 290 in cell B5
11 Enter 460.358 in cell B6.
Note that the values are Right Justified irre-
spective of whole values or values with a deci-
mal point.If a value displays as number signs,
or scientific notation (such as 1.23E+04) as
shown in Fig 2 in cell D8, the value is too long
to fit into the cell. You need to widen the
column width.

Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108 319

13 Close the worksheet without saving by clicking the Fig 4
lower close button on the right top corner of the
worksheet as shown in (Fig.3) and don't exit excel.
Fig 3

Exit Excel

14 Select Don't Save button.

Close Worksheet
15 Get it checked with the Instructor.

Note: Lower close button closes the worksheet

and upper close button is used to exit excel.
An information dialog box appears as shown
in the (Fig. 4)
__________
TASK 7: Create a table and save the worksheet
1 Create an new worksheet as follows: File  New  Blank Document  Create as shown
in Fig 5.
Fig 5

2 Type the labels and numbers as shown in the Fig 6 Fig 6

3 Select the cells A1 to E11.

320 Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108

 Fig 2

3 Click the right hand side of the mouse and choose

delete slide to delete the default slide as on (Fig. 3)
Fig 3

Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108 321

4 Click New slide to choose "Two content layout" from the
home tab as on (Fig. 4) or Click layout and select "two
content layout" slide without deleting the default
appeared slide
Fig 4

Note: A two content layout displayed on the

screen as on (Fig. 5)

Fig 5

__________
322 Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108
TASK 10 : Insert a pictures

1 Click the "Add title" and Type "THE LION AND THE 3 Apply visual style by choosing Quick style as subtle
MOUSE" in capital give the font size 40 and font faces effect purple accent 4 from the home tab as on fig 7
as CASTLLER, theme colour as red accent 2, Darker
Fig 7
50% italicized it from Font of home ribbon
2 Click "Centre on paragraph" from home tab to centre the
text as on (Fig. 6)
Fig 6

Note : The layout is shown as on (Fig 8)

Fig 8

4 Click the add text of the right hand side of the place Note : the default picture library folder of the
system appears
holder and click insert picture from file tab 5 Choose a pic1.jpg from the picture library and click
insert key as on (Fig 9)
on the holder

Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108 323

 Fig 9

Note : the added picture is seen on the screen

as on (Fig 10)

Fig 10

324 Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108

6 Drag the picture edges and set it as on (Fig 11)
Fig 11

7 Click the add text left hand side of the place holder and 8 Block the text and apply faces as comic sans MS, 14
type the following text by removing the bullet by pressing as size, from the font and line spacing as 2.0 and justify
backspace. it by choosing from paragraph menu
Once when a Lion was asleep, a little Mouse Note : The typed text is shown on the layout as
began running up and down upon him. This on Fig 12
soon wakened the lion, who placed his huge
9 Click New slide to perform the same effects as did on
paw upon him and opened his big jaws to
step 8, on the second slide, delete the "add title text"
swallow him.
place holder
"Pardon, O king!" cried the little Mouse, "For-
give me this time, I shall never repeat it and I 10 Type the following text and add pic2.jpg on the two
Shall never forget your kindness. And who content place holder.
knows, but I may be able to do you a good turn Sometime later a few hunters captured the
one of these days?" king and tied him to tree while they went in
The Lion was so ticked at the idea of the mouse search of a wagon to carry him on.
being able to help him, that he lifted up his paw
and let him go.
Fig 12

Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108 325

 Just then the little mouse happened to pass by, 11 Click header and footer from insert menu,
and seeing the sad plight in which the lion was, Note : a header footer window appears on the
ran up to him and soon gnawed away the ropes screen, choose slide and put a tick mark on the
that bound the king of the beasts. "Was I not footer and click apply to all as on Fig 14
right?". Said the little Mouse, very happy to
help the lion. Note: Now an invoked footer box is shown on
MORAL: Little friends may prove great friends the first slide type page 1 and page 2 on the
second slide.
Note: The Second slide appears as on Fig 13

Fig 13

Fig 14

326 Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108

TASK 11: Apply Themes and effects
1 Click design from the ribbon and choose theme menu Note : the picture gets shrinked drag it to get set
and apply "paper" and the slide turn to the theme as on (Fig 15)
selected

Fig 15

2 Apply "wipe" , from transition to the slide menu

3 Apply " breeze" sound , 1:50 on duration, 1:00 from after
in Timing of transition ribbon Fig 15 (a)

Fig 15a

4 Click preview to view the applied affects to the slide 7 Click File and choose print option
5 Click slide show menu on the ribbon and click the "from Note : A default printer will be selected and the
beginning" button to view the slide show as on preview of the page is shown as on (Fig. 18)
Fig 16 & 17
8 Click print.
6 Click "End of the slide show, click exit" to exit the
screen

Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108 327

 Fig 16

Fig 17

328 Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108

 Fig 18

__________
TASK 12: Save and closing a slide

1 Click file and choose "Save As" option to save the slide 2 Close the "presentation 1.pptx" by clicking file and
as "presentation 1" as on (Fig 19) choose close
Note: Save as window appears on the screen 3 Check with the instructor.
on the location bar. Choose desktop select
computer literacy folder and save the file by
clicking save

Fig 19

Power: Wireman (NSQF Level - 4) Exercise 1.17.107 & 108 329

Power Exercise 1.17.109
Wireman - Computer Awareness

Internet Practicing – Browsing/Creating Email, Downloading

Objectives: At the end of this exercise you shall be able to
• use search engine to browse
• browse a website through web browser
• download file from website and print the downloaded file
• create an Email account
• add contacts, compose and attach document, Send emails
• check the mail and sign out.

Requirements
Tools and Instruments/equipment
• Intel core i3 or higher with Windo-ws 7
operating system
• High speed Internet connection

PROCEDURE
TASK 1: Using search engine to browse

Note to the Instructor: Set Google as the home Note : A home page google appears on the screen
page as Fig. 1
1 Choose Internet explorer and click it.
Fig 1

2 Type www.DGET.nic.in on the Address bar and press

enter as on Fig 2.
Fig 2

330
 Note : The DGET website appears on the screen as 3 Click the Annual report as shown in Fig. 3 of the
on Fig 3 Website and view the various report like Child work,
social security, women and work and etc.

Fig 3

__________
TASK 2: Down loading and printing of syllabus
1 Select and click the trade syllabus from the home page
of DGET (Fig. 4)
Fig 4

Power: Wireman (NSQF Level - 4) Exercise 1.17.109 331

 Note: A Fig. 5 appears on the screen.

Fig 5

2 Select and click CRAFTSMAN TRAINING SCHEME Note: List of Engineering and Non-Engineering
(CTS) trades appears on the screen as on Fig 6

Fig 6

332 Power: Wireman (NSQF Level - 4) Exercise 1.17.109

3 Scroll down the screen with the mouse and select the 4 Click the selected trade which is under lined in blue
trade syllabus Hyberlink as on Fig 7
Example: Trade name "Draughtsman (Mechanical)"

Fig 7

Note: The syllabus of Draughtsman mechanical

appears on the screen as on Fig 8

Fig 8

5 Click the Floppy button Note : A screen appears on the screen to save
it as on Fig 9
to save and download
Note: The saved file is in pdf format so acrobat
the syllabus reader has to be loaded in the system (or) it can
be downloaded from the internet

Power: Wireman (NSQF Level - 4) Exercise 1.17.109 333

 Fig 9

6 The downloaded file can be opened by clicking show all

the download button as on Fig 10.

Fig 10

__________
TASK 3: Create an Email Account

Note to the Instructor: Make the trainees to 1 Choose Internet Explorer and Click to open it on the
create accounts as itistud as the primary name window desktop.
and secondary in increasing order of number Note: The home page appears on the screen.
series, in both yahoo and gmail. (Fig 1)
Example : itistudtwo, itistudthree etc. 2 Type www.yahoomail.com on the address bar and click
enter

Fig 1

334 Power: Wireman (NSQF Level - 4) Exercise 1.17.109

 Note: A yahoo Account screen appear as on
(Fig 2)
3 Click "Create New Account"

Fig 2

Note : The following window appears on the 7 Type password as "sachin1@iti" and retype the
screen as on (Fig 3). same

4 Type "iti" in First Name box, "studone" Second box, 8 Type itistudone@gmail.com for alternate email

5 Choose Male in Gender, Birthday January, 24, 9 Choose "In secret question 1", select other question
1994, India in Country, English in Language from the below dropped down box and type the name of
the ITI: ITI
6 Choose "itistudone@yahoo.com

Fig 3

Power: Wireman (NSQF Level - 4) Exercise 1.17.109 335

10 Choose "In secret question 2", select "Name the sports 11 Type the quote shown
favourite?" : Sachin
Note: the "create my account screen" with
Note: The secret question 1 should be related to filled data appears as on Fig 4
email id, secret question 2 should be related to
12 Click the create an account button
your password so that it can be easily
rememberable when you forget it

Fig 4

Note : A successful Registration shown in Fig 5. Note: The yahoo mail window appears on the
screen as on Fig 6.
13 Click continue button.

336 Power: Wireman (NSQF Level - 4) Exercise 1.17.109

Fig 5

Fig 6

__________
Power: Wireman (NSQF Level - 4) Exercise 1.17.109 337
TASK 4: Add contacts

1 Click the "CONTACTS" from the yahoo mail menu. 4 Click save button after filling it
Note : the following window appears on the Note: the following screen is shown Fig 9
screen Fig 7
Note to the Instructor: Make the trainees to add
2 Click the "Add a New Contact" button to append more newly created contact of yahoo and
contacts gmail accounts
Note: A screen appears as on Fig 8 Example: itistudtwo, itistudthree etc.
3 Type iti in firstname, Studone in Middle name,
itistudone@gmail.com and fill the required field

Fig 7

338 Power: Wireman (NSQF Level - 4) Exercise 1.17.109

 Fig 8

Fig 9

__________
Power: Wireman (NSQF Level - 4) Exercise 1.17.109 339
TASK 5: Composing and Sending mail with attachments
1 Click INBOX button, and choose COMPOSE MESSAGE Note: The following Fig 10 appears on the
screen

Fig 10

2 Click + sign of TO box 3 Choose the contact itistudone@gmail.com and

click "done"
Note: Fig 11 appears on the screen

Fig 11

4 Type "My Power point presentation" In Subject

5 Click "Attachments"
340 Power: Wireman (NSQF Level - 4) Exercise 1.17.109
 Note: The attachments window is invoked and Your Friend
select "presentation 1 .pptx" from the folder
computer literacy on the desktop and click Note : Select Blushing from emotions, Click
open as on Fig 13. Format, choose Italic for the body of the letter,
click stationary and apply Goth rose as Back-
6 Type the following ground click spell check (abc) button to correct
Hi Friend, the text.

How are you?, Hope you are fine, I have created a Power
point presentation were it describes a story with a
moral, Enjoy it
With Love

Fig 12

The finished screen appears as Fig 13 Note : The (Fig 14) appears as the mail is sent.
7 Click send button

Power: Wireman (NSQF Level - 4) Exercise 1.17.109 341

 Fig 13

Fig 14

__________
342 Power: Wireman (NSQF Level - 4) Exercise 1.17.109
TASK 6: Checking mails and sign out
1 Click "INBOX" Note : If you have attachments just click
Note : the unread messages are shown in the download and save the file.
inbox as on Fig 15. The file gets download in the default download file
2 Click the mail named "ITI STUDONE" location.

Note : the Fig 16 appears on the screen. 3 Click "sign out" to come out of yahoo mail as on
Fig 17.
4 Check with the instructor.

Fig 15

Fig 16

Power: Wireman (NSQF Level - 4) Exercise 1.17.109 343

 Fig 17

__________

344 Power: Wireman (NSQF Level - 4) Exercise 1.17.109