Preparation of electrical installation

1. Identification of electrical installation accessories

1.1 Types of Conduits

The commonest method of installing cables is to draw them in to a conduit. The conduit can be
steel or plastic. Steel conduit is made in both light gauge and heavy gauge, of which heavy gauge
is much mire frequently used.
In general conduits can be classified as:
i. Light gauge steel- plain (un screwed) conduit
ii. Heavy gauge steel-screwed conduit
iii. Flexible conduit
iv. PVC conduit

i. Light gauge steel conduit: This type of conduit is used with special grip fittings. It is
available with an external diameter of 12mm, 16mm, 19mm, 25mm, 31mm, 38mm and
50mm.
In general light gauge is the cheapest and quickest of the conduit installations but should be used
where the locations is dry and there is little likely hood of mechanical damage.
ii. Heavy gauge screwed steel conduit: Though it is very expensive, this type of conduit
provides a permanent installation with a maximum of protection for the cables. The joints
into fittings are by means of screw threads, which provide mechanical strength and good
electrical continuity. These are available in approximately 3-meter lengths and are
threaded at the two ends.
iii. Flexible steel conduit: This usually consists of light galvanized steel strip spirally wound
and, to some extent, inter locked, so as to form a tube. It is made in size from 19mm to 50
mm internal diameter and in two grades: non- water tight and water tight. It can be made
with an external covering of PVC sleeving.
Flexible conduit is available in lengths up to 250meter. So no coupling is required and hence no
threading. Since the conduit is flexible and are easily bent so no elbow is required. For
connecting a flexible conduit to ordinary conduit, special brass adapters are used. It is necessary
to run an earth wire through the flexible conduit, as the spiral formation does not provide
efficient continuity.
One of the most common uses of flexible conduit is for protecting the final connections to
motors. It has the additional advantage of reducing the transmission of vibration. However, the
flexible conduit is costlier than the rigid conduit.
iv. PVC conduit: This type of conduit wiring is finding wide applications in internal wiring
because it is light in weight, shock proof, anti- termite, self extinguishing and fire
resistant, acid and alkaline resistant.
Such conduits can be used for surface, recessed or concealed type wirings. Conduits may be
joined by the screwed or plain type of couplers (sockets) depending up on weather conduits are
of the screwed type or plain type. In long runs of conduits, inspection type couplers are provided.
Fixing method shall be the same except that in this case spacing shall be at every 60 cm instead
of 1.0 m in case of metallic conduit.

1.2 Types of Junction Box

Conduit Boxes; Conduit boxes are used in surface conduit wiring as well as concealed conduit
wiring. The conduit boxes are of different designs. These serve the following purposes:
1) For providing connections to light, fan and other points. The conduit boxes serving
the purpose are known as out let boxes because conduit terminates at the boxes. These
boxes may have entry either from side or from back or from sides.
2) For pulling of cables in to the conduit boxes serving this purpose are known as
junction boxes.
Location of boxes
In surface conduit wiring, all conduit boxes and fittings are fixed on the surface of the wall. A set of
bent up conduit ends is required when it enters in to the box. Because the box stands ‘out’ from the
wall. If these set is to be avoided, the box may be partially sunk in to the wall or ceiling.
In concealed conduit wiring, the depth at which conduit is sunk in to the wall or ceiling must be so
adjusted as to bring the cover of the boxes in flash with the finished plastered surface of the wall
while the conduit remains covered under plaster.
The outlet box may be square, rectangular or of any other shape with varying depths depending up
on requirements i.e. If the thickness of wall is not enough, then shallow iron box may be used and
where thickness of wall is more, a deep box may be used.

Types of lamps &Lamp holders

Incandescent lamp
The function of lamp holder is to hold the lamp and to connect it electrically to supply
terminals. The lamp holders may be made of brass with porcelain insulation for giving
connections to lamp between two plungers. These may be made of Bakelite. The former are
more durable but may give shock incase of loose connections. The lamp holders may be
classified as under

a. Batten lamp holder: this type of holder is fixed over round blocks or wooden boards with
three wood screws. The connections to the batten holder are given from beneath round block
by drilling two holes for the purpose. These may be of brass or Bakelite.
b. Pendant lamp holder: When lamp holder is made to hang down ward from the ceiling
rose with flexible wire, a pendant holder is used. It can also hold a lampshade. These may be
of brass or Bakelite.
c.Angle lamp holder This is used where the lamp is required to be fixed directly on the wall on
round block. The connections to the angle holder are given from behind it through round
block. The angle holders may be made of brass or Bakelite with brass plunger.
d. Swival lamp holder: - The swival lamp holder are designed for controlled wide-angle
directional lighting, which are used for lighting of shop windows, show cases etc. It consists
of a ball and socket joint fitted between back plate and lamp holder.
e.Bracket with holder: - The brass bracket may be given any shape but generally direction of
bulb holder is towards floor at some angle. In government buildings, the brackets used are
made of wood having batten holder fixed at right angle to it length. The holder has the
provision to hold the lampshade. Such lamp holders are provided with fittings which make
them watertight so that these are used out side the houses or for street lighting.
1.4 Types of switches

I. One-way switches. It is used to make ON or OFF a lamp or lamps from only one location. It is
commonly used in kitchen room.
L

Switch

II. Two way switch

The basic function of two-way switch is to divert the flow of current to either of the two directions.
The two-way switch can be used for instance, to control one lamp or lamps from two different
locations. It is commonly used in bedroom.

N
P

III. Intermediate switch

A switch with all four independent terminals for four connections is called intermediate switch or
four-way switch. Many of the four way or intermediate switches have the terminals arranged in the
same relative position as those of a double pole switch. Broadly, the function of this switch is to
change the path of current from one wire to the other when wire leaves the switch .It also provides
through connection. For instance, when one lamp is to be controlled from more than two locations
say three or even more. It is commonly used in wide room with many entrances such as meeting hall
 N
P

Intermediate Switch

IV. Ganged switch: - Switches can be combined together so as to control lamps in a group from one
location. It is commonly used in workshops.

SW

1.5 Types of Socket outlet

The function of socket outlet is to provide tapping from socket terminals to the electrical fixture such as radio;
able fan and heater etc .the socket outlets are of two types:
. Two or three pin 5 Amp.
. Three pins 15 Amp. The difference between 5 Amps. and 15 Amp. Sockets are in there sizes which amounts
’s rating. The third terminal is for holding the earth wire. These are available in market as tumbler (for surface
wiring) and flush sockets (for concealed conduit wiring). The three pin socket outlets are of two types (a)
Amp.for table fan, table lamps etc and (b) 15Amp.sockets for heater, iron etc.

1.6 Types of Protective devices

On consumer installations, the two types of protection used against over loads and short circuit faults are
1.Fuses
2.Circuit breakers
 uses operate on the basis of the heating effect (I 2 R) of the excess current which melts the fuse element. There
re three main types of fuses: - The rewirable, cartridge and the HBC (high rating capacity) fuse; the latter is
evelopment of the cartridge type.
Three terms are used in connection with fuses:
Current rating This is the maximum current that a fuse will carry indefinitely with out undue deterioration of the
use- element.

Fusing current This is the minimum current that will ‘blow’ the fuse.

Fusing factor This is the ratio of the minimum fusing current to the current rating.

F using factor = minimum fusing current  1

Current rating

Rewirable fuses

The rewirable type of fuse consists of a porcelain (usual material) bridge and base. The bridge has two sets of
ontacts, which fit in to other contacts in the base. The fuse element, usually tinned copper wire, is connected
etween the terminals of the bridge. An asbestos tube or pad is usually fitted to reduce the effects of arcing when
he fuse element melts.
The rewirable fuse is a simple and relatively cheap type of over current protective device and is still widely used
espite several disadvantages including:
a. The fact that it is reparable enables the wrong size of the fuse wire (element) to be used.
b. Undue deterioration of the fuse elements due to oxidation.
c. Lack of discrimination. This means that normal starting surges (e.g. when motors etc, are
switched on) are “seen” by the fuse as an over load and will therefore break the circuit.
d. Damage, particularly in conditions of severe short circuit.
The fusing factor for rewirable fuse is about 2.

Cartridge fuses
The obvious disadvantage of the rewirable type of fuse led to the development and use of the cartridge type fuse.
The fusing factor of this fuse is about 1.5.

High -Rapture – Capacity (HRC) fuses

The high breaking capacity fuse (HBC) has its fusing characteristics carefully controlled by the manufacturer. As
s name implies it can safely interrupt very large currents. The fuses are often used to protect large industrial
oads and main cables. The cartridge barrel is of high-grade ceramic able to withstand the shock conditions when
heavy fault current is interrupted. Except for very low ratings the fuse element is made from pure silver. The
iller is powdered silica, carefully dried before use. An indicator is provided to show when the fuse has blown.

CIRCUIT BREAKERS

It is a device designed to open and close a circuit by non- automatic means, and to open the circuit
automatically on a predetermined over current without injury to itself when properly applied within
its rating. So a circuit breaker is combination device composed of a manual switch and an over
current devices.
Essentially a circuit breaker consists of a carefully calibrated by metallic strip. As current flows through the strip,
eat is created and the strip bends. If enough current flows through the strip, it bends enough to release a trip that
pens the contacts, interrupting the circuit just as it is interrupted when a fuse blows or a switch is opened. In
ddition to the bimetallic strip that operates by heat, most breakers have a magnetic arrangement that open the
reaker instantly incase of short circuit. A circuit breaker can be considered a switch that open itself incase of
verload.
Circuit breakers are rated in amperes just as fuses are rated. Like fuses, breakers are tested in open air to carry
10% of their rated loads indefinitely without tripping. Most breakers will carry 150% of their rated load for
erhaps a minute; 200% for about 20 second.
Standard rating: Both fuse and circuit breakers are available in standard ratings of
6,10,16,20,25,35,50,53,80,100,125,160,224,250,300 and large sizes.

Comparison between MCB versus convectional fuses

MCB Conventional fuses

1. Protection Some times, fuse wire of proper rating is
MCB instantly switches off the supply not used which results in non-
automatically if there is a short circuit, disconnection (melting) of fuse wire in the
overload or earth fault. It thus prevents event of short circuit, or power overload.
damage to expensive wiring and the This can lead to electrical accidents, as the
risk of fire. tripping is essential in such cases.
2. Safety TO replace a blown fuse in between live
Re-starting power supply after tripping current carrying points is potentially
due to over load or short circuit is easy. dangerous especially in the dark. The fuse
Just switch on the MCB like switching wire may go loose even if replaced and this
on a lamp, which any person can do. may be dangerous while fixing the fuse.
3. Convenience The system using rewirable is not
The MCB needs no maintenance and convenient as the exact size of fuse wire
repairs. It doesn’t deteriorate with time. may not be available as the time of wiring.
Also complete kit of hand tools has to be
kept ready all the time.
4. Look The fuse board is not compact one and
The board where MCB is installed large enough to be hidden.
gives a beautiful look as it is compact
and elegant

1.7 Types of wires and Cables

The terms wire and cable are used more or less synonymously in house wiring. Strictly speaking, single wire,
may be or covered with insulation is known as a wire and several wires stranded together are termed as wire
and conductors covered with insulation are termed as cables.
The necessary requirements of a cable are that it should conduct electricity efficiently, cheaply and safely.
This should neither be so small so as to have a large internal voltage drop nor be too large so as to cost too
much. Its insulation should be such as to prevent leakage of current in unwanted direction and minimize risk
of fire and shock
A cable consists of three parts:
a. The conductor or core: the metal wire or strand of wires carrying the current.
b. The insulation or dielectric; a covering of insulating material to avoid leakage current from the
conductor.
c. The protective covering for protection of insulation from mechanical damage.

Conductor materials used in cables

Copper and aluminum are the materials used as conductors in power and lighting cables.
1.Copper. Though silver is the best conductor but due to it’s higher cost it is hardly used
anywhere. The next best conductor is, copper. It is cheaper comparatively.
2.Aluminum. Aluminum is frequently used in place of copper for bare electric cables used for
long distance power distribution.
The only application of aluminum cable for wiring in buildings is for a continuous bus-bar
system of distribution, used sometimes in blocks of flats or office buildings for rising mains
and sub-mains of larger sectional area.
Types of cables used in internal wiring
The wires employed for internal wiring of buildings may be divided in to different groups according
to the type of conductor, the number of cores, the voltage grading, and the type of insulation used.

According to the number of cores, the cables may be divided in to the classes known as single core,
twin core, twin core with EEC (earth continuity conductor) cables etc.
According to voltage grading the cables may be divided in to two classes: 250/ 440volt and 650/
1100-volt cables.
Cables classified according to the type of insulation are: -

1.Vulcanized Indian rubber (VIR) cables:

VIR cables are available in 250/ 440 volts as well as in 650/ 1100voltage grades and are used for
general conduit wiring.
2.Lead sheathed cables: these cables are also available in 250/ 440-volt grade and are used for
internal wiring where climatic condition has moisture. The lead sheathed cable is a vulcanized
rubber insulated conductor covered with a continuous sheath lead. The sheath provides very
good protection against the absorption of moisture and sufficient protection against mechanical
injury and can be used without casing or conduit system. It is available as a single core, flat twin
core, flat three cores and flat twin core with an earth continuity conductor.
3.PVC cables: These cables are available in 250/ 440 volt and 650/1100 volt grades and are used
in concealed wiring system. Since PVC is harder than rubber, PVC cables do not require cotton
tapping and braiding over it for mechanical and moisture protection.

4.Weatherproof cables: These cables are used for out door wiring and for power supply. These
cables are not affected by heat or sun or rain. These cables are either PVC insulated or
vulcanized rubber-insulated conductors being suitably taped (only in case of vulcanized rubber
insulated cable) braided and then compounded with weather resisting material. These cables are
available in 250/ 440 volt and 650/ 110 volt grades.
5. Flexible cords and cables: A flexible cord consists of wires either silk or cotton or plastic
covered. Plastic over is more popular as it is available in various pleasing colors. Flexibility and strength
is by using conductors having large number of strands.
Most stranded conductors are built upon a single central conductor. Surrounding this conductor is layers of
wires in a numerical progression of 6 in the first layer, 18 in third layer, and so on. The number of wires
contained in most common conductors is to be found in the progression 7,19,37,61, 127.
Stranded conductors are used in both fixed wiring cable and flexible cords, the latter being flexible cables
not exceeding 4mm2. Conductors for fixed wiring up to 25mm2 have seven strands; for example a 6mm2
conductor has seven strands each of 1.04mm diameter (7/1.04).
Colors of conductors:- The wiring regulations require that all conductors have to be
identified by some means to identify their function. For example, according to the British
wiring regulation, the phase conductor of three-phase system are colored red, yellow and
blue with the neutral colored black. Protective colors are identified by green/yellow.

Color identification of bare conductors and cable cores.

(EEPCO’s regulation)

Color identification of cores of rubber of

PVC insulated non- or flexible cable or
Function sleeve or disc to be applied to conductor or
cable core

Earthing White

Live of Ac single phase circuit Green

Neutral of Ac single phase or three phase Black
circuit
Phase R of three phase ac circuit Green
Phase S of three phase Ac circuit Yellow
Phase T of three phase Ac circuit Red

General specification of cables: The complete specification of a cable will give the following
information:
i. The size of the cable
ii. The type of conductor used in cables (copper or aluminum)
iii. Number of coarse that the cable consists of (i.e. single core, twin core, three cores, twin
core with ECC etc.
iv. Voltage grade
v. Type of insulation, taping, braiding and compounding

1.8 Types of distribution board.

There are three types of distribution boards:

1. Those fitted with rewirable fuse links
2. Those fitted with HBC fuse links.
3. Those fitted with circuit breakers.
 As already explained there are many objections to the use of rewirable fuses, as there is very little
guarantee that the fuse link chosen at the time of the installation will not be replaced by a larger fuse link
there is much to be said for choosing distribution boards fitted with MCBs or HBC fuse links. Distribution
boards fitted with miniature circuit breakers are more expensive in there first cost, but they have much to
commended them, specially as they can incorporate an earth leakage trip. Miniature circuit breakers are
obtainable in ratings from 5A to 60A, all of which are of the same physical size, and are there fore easily
interchangeable.(they must not of coarse be interchanged without first making sure that the cables they
protect that are of the correct rating.)
Distribution boards should preferably be sited as near as possible to the center of the loads they are
intended to control. The sub distribution boards are employed near the load if the building is large. This
will minimize the length and cost of final circuit cables but this must be balanced against the cost of sub
main cables.
Other factors which will help to decide the best position of distribution boards are the availability of
suitable walls, the ease with which circuit wiring can be run to the position chosen, accessibility for
replacement of fuse links, and freedom from dampness and adverse conditions. (If exposed to the weather
or damp conditions, a distribution board must be of the weatherproof type.)
Distribution board is recessed into a wall, which is constructed of combustible material such as wood; the
case must be made of metal or other non- combustible material.

1.9 Fixing accessories

There are several methods of fixing conduits, and the one chosen generally
depends up on what the conduit has to be fixed to.
Conduit Clips
Conduit clips take the form of a half saddle, and have only one fixing lug. They are certainly more satisfactory
han pipe hooks, although the only reason for using clips instead of saddles it to save an additional fixing screw.
They are not satisfactory if the conduit is subjected to any strain, and in any case their use gives a very
arsimonious impression.
Ordinary saddles
Ordinary saddles are most commonly used and should be fixed by means of two screws –not nails. They provide a
ery secure fixing and should be spaced not more than 1.3 m apart.
pacer bar saddles
pacer bar saddles are ordinary saddles mounted on a spacing plate. These plates are 3 mm thick for conduits up
o 40 mm diameter, and 5 mm for larger sizes of conduit .The real function of the spacer bar saddle is to prevent
he conduit from making intimate contact with damp plaster and cement walls and ceilings which would result in
orrosion of the conduit and discoloration of the decorations.
Distance saddles
These are designed to space conduits approximately 10 mm from the wall or ceiling. Distance saddles are
enerally made of malleable cast iron they are much more substantial than other types of saddles, and they space
he conduit from the fixing surface they provide better protection against corrosion.
The use of this type of saddle eliminates the possibility of dust and dirt collecting behind and near the top of the
onduit where it is generally inaccessible. For this reason distance saddles are usually specified for hospitals,
itchens, and other situations where dust traps must be avoided

4. Preparation of electrical wires, Cables, Conduits and other related

materials

4.1 Selection of wires

The word wire applies to a single electrical conductor. The conductor may be one strand of
material or several strands twisted together.
Wires are used for carrying current in an electrical installation. There are different types of
wires used in electrical installation.
It consists of a core, which conducts electricity, and insulation cover, which doesn’t conduct
electricity
1. Core
2. Insulation

4.1.1 Solid Wire

The core of an insulated wire for general electrical installation work is mostly made of copper and in

some cases of aluminum.

The core of some insulated wire consists of a single strand of conductive material.

Fig x
4.1.2 Flexible/Stranded wire

There are also insulated wires with a core consisting of a few strands of wire. This type of wire is
called multi-strand wire (Fig xx)

Fig xx
Multi –strand wires with a core consisting of many fine strands of wire. They are used for such
electrical installations where the connecting lines are moved a lot.(fig xxx)

Fig xxx

WIRE SIZE

A group of wire sizes has been established to cover all wiring needs. The
empirical values for the allocation of the core cross-sections; maximum current and
application ranges can be read off from the table for domestic installations.

Table-3 wire size for Domestic installation

Wire cross- Max.current Application range

section
0.75 6A Lighting circuits
1 10 A Lighting circuits
1.5 16 A Lighting and socket outlet
circuits
2.5 20 A Space heater
4 25 A Washing machine
6 35 A Flow type heaters
10 50 A Sub-distribution
16 63 A House service circuit

THINGS TO BE CONSIDERED WHEN SELECTING THE RIGHT CONDUCTOR SIZE

1. Conductor materials:- copper is the standards. For aluminum or copper clad
aluminum the rule of thumb is to use wire two sizes larger than specified for copper.
2. Maximum expected current load:-conductor size (based on ampacity) must be
sufficient ton carry the maximum expected load safely.
3. Wet or dry location:- conductor insulation must be suitable to moisture conditions.
4. Area air temperature:- Areas where air temperature are usually above 300 C
require larger conductors and special insulation.

4.3.1-cutting wires to specified length

4.2 cables
In the electrical industry the words wire and cable have specific meanings. You must
know these meanings to understand the National electrical code(NEC), to order material from a
catalogue or to talk with electrical suppliers and contractors.
Cable the combination of insulated conductors and grounding wire enclosed in an
outer covering.
The terms wire and cable are used more or less synonymously in house wiring. Strictly speaking,
single wire, may be are or covered with insulation is known as a wire and several wires stranded
together is known as a cable. But in practice bare conductors, whether single or stranded together is
learned as wire and conductors covered with insulation are termed as cables.

The necessary requirements of a cable are that is should conduct electricity

efficiently, cheaply and safely. This should neither be so small so as to have a
large internal voltage drop nor be too large so as to cost to much. Its insulation
should be such as to prevent leakage of current in unwanted direction and thus
to minimize risk of fire and shock.
A cable consists of three parts:
a) The conductor or core; the metal wire or strand of wires carrying the current.
b) The insulation or dielectric: a covering of insulating material to avoid leakage
current from the conductor,
c) The protective covering for protection of insulation from mechanical damage.

Conductor materials used in cables

Copper and aluminum are the materials used as conductors in power and
lighting cables.

1. Copper though silver is the best conductor but due to its higher cost it is
hardly used anywhere. The next best conductor is copper. It is cheaper
comparatively.

The electrical receptivity of pure copper at 20 C is 1.786 10 ohm-m. It is

mechanically strong hard extremely tough, durable and ductile. It is highly
resistive to corrosion, oxidation and pitting.
2. Aluminum. Aluminum is frequently used in place of copper for bare electric
cables used for long distance power distribution. The electrical conductivity
of aluminum is about 60% of that of copper (2.87 10 ohm-m at 20 C) so
for the same resistance for a given length, the aluminum required will be
1.61 times that of copper in volume and 1.26 times of that of copper in
diameter. The only application of aluminum cables for wiring in buildings is
for continuous bus - bar system of distribution, used sometimes in blocks of
flats or office buildings for rising mains and sub - mains of larger sectional
area.
4.2.1 Selection of cable types

TYPES OF CABLES USED IN INTERNAL WIRING

The wires employed for internal wiring of buildings may be divided into different
groups according to the type of conductor, the number of cores, the voltage
grading, and the type of insulation used.

According to the number of cores, the cables may be divided into the classes
known as single core, twin core with ECC (Earth continuity conductor) cables
etc.

According to voltage grading the cables may be divided into two classes:
250/440 volt and 650/1100 volt cables.

Cables classified according to the type of insulation are

1. Vulcanized Indian Rubber (VIR) Cables:

VIR cables are available in 250/440 volt as well as in 650/1100 volt grades
and are used for general conduit wiring.

2. Lead sheathed cables: these cables are also available in 250 / 440 volt
grade and are used for internal wiring where climatic condition has
moisture. The lead sheathed cable is a vulcanized rubber insulated
conductor covered with a continuous sheath of lead. The sheath provides
very good protection against the absorption of moisture and sufficient
protection against mechanical injury and can be used without casting or
conduit system. It is available as a single core, flat twin core, flat three core
and flat twin core with an earth continuity conductor.
3. PVC Cables: These cables are available in 250/440 volt and 650/1100
volt grades and are used in concealed wiring system. Since PVC is harder
than rubber, PVC cables do not require cotton taping and braiding over it
for mechanical and moisture protection.
4. Whether Proof cables: These cables are used for outdoors wiring and
for power supply. These cables are not affected by heat or sun or rain.
These cables are either PVC insulated or vulcanized rubber-insulated
conductors being suitably taped (Only in case of vulcanized rubber
insulated cable) braided and then compounded with weather resisting
material. These cables are available in 250/440 volt and 650/1100 volt
grades.
5. Flexible cords and cables: A flexible cord consists of wires either silk or
cotton or plastic covered. Plastic cover is more popular as it is available in
various pleasing colors. Flexibility and strength is by using conductors
having large number of strands.

Most stranded conductors are built upon a single central conductor. Surrounding
this conductor are layers of wires in a numerical progression of 6 in the fist
 layer, 12 in the second layer 18 in third layer, and so on. The numbers of
wires contained in most common conductors are to be found in the
progression 7,19,37,61,127

Stranded conductors are used in both fixed wiring cable and flexible cords, the
letter being flexible cables not exceeding 4mm . Conductors for fixed
wiring up to 25mm have seven strands; for example a 6mm conductor
has seven strands each of 1.04mm diameter (7/1.04).
Colours of Conductors: - The wiring regulations require that all conductors have
to be identified by some means to identify their function. For example,
according to the British wiring regulation, the phase conductor of three -
phase system are coloured read, yellow and blue with the neutral coloured
black. Protective colours are identified by green / yellow.
Colour identification of bare conductors and cable cores
(EELP's Regulation)

Co lour identification of core of

rubber of PVC insulted non - or
Function flexible cable or of sleeve or dise
to be applied to conductor or
cable core
Earthing White
Live of .c single - phase circuit Green
Neutral of a.c single - phase or three - Black
phase circuit
Phase R of three - phase a.c circuit Green
Phase S of three - phase a.c circuit Yellow
Phase T of three - phase a.c circuit Red

General Specification of cables. The complete specification of a cable will give

the following information:
I) The size of the cable
II) The type of conductor used in cable (copper or aluminum)
III) Number of cores that the cable consists of (i.e single core,
twin core, three core, twin core with ECC etc.
IV) Voltage grade
V) Type of insulation, taping, braiding and compounding.
4.2.1 Selection of cable types

The most widely used types of nonmetallic (plastic covered) and armored (metal
covered) cables are described below:

Non-metallic cable

Three types non-metallic cables in general use for home wiring .All three are light in
weight easy to work with, and relatively inexpensive
 NM type consists of insulated conductors wrapped in paper with a fiber filler added,
which are enclosed in a plastic cover.
NMC type is similar to NM, but is modified to withstand some moisture. In NMC cable
the insulated conductors are in closed in solid plastic.
Type UF (Under feeder) cable is similar in appearance to NMC, but its outer cover is
tougher and less porous so that it can be used in all wet locations and underground.

typical insulated conductors

Construction of non-metallic cable

Armored cable

Armored cable does the job electrically as non-metallic cable. The main advantage of
armored cable is the protection provided by the metal covering. The main disadvantage
is that the metal is subject to rust and corrosion in damp location.

Construction of armored cable

4.2.2 Cutting Cables

‘Please use the procedure to cut cable which is mentioned on cutting

wires’

4.2.3 Trimming of cables

4.3 Conduits
The commonest method of installing cables is to draw them into a conduit.
The conduit can be steel or plastic. Steel conduit is made in both light
gauge and heavy gauge of which heavy gauge is much more frequently
used.

4.3.1 Types of conduits

In general conduits can be classified as:

I) Light gauge steel - plain (unscrewed ) conduit

II) Heavy gauge steel screwed conduit
III) Flexible conduit
IV) PVC conduit

i. Light Gauge steel conduit : This type of conduit is used with

special gip fittings. It is available with n external diameter of
12mm, 16mm, 19mm, 25mm, 31mm, 38mm and 50mm.

In general light gauge is the cheapest and quickest of the conduit installations
but should be used where the location is dry and there is little likelihood of
mechanical damage.

ii. Heavy Gauge screwed steel Conduit: Though it is very

expensive, this type of conduit provides a permanent
installation with a maximum of protection for the cables. The
joints into fittings are by means of screw threads with
provide mechanical strength and good electrical continuity.
These are available in approximately 3-meter lengths and
are treaded at the two ends.
iii. Flexile steel conduit: This usually consists of light galvanized
steel strip spirally wound and, to some extent, interlocked, so
as to form a tube. It is made in size from 19mm to 50mm
internal diameter and in two grades: non - water tight and
water tight. It can be made with an external covering of PVC
sleeving.
Flexible conduits are available in lengths up to 250meter. So no coupling is
required and hence no threading. Since the conduits are flexible and are
easily bent so no elbow is required. For connecting a flexible conduit to
iv. PVC conduits
These conduits are available in similar sizes and types of fitting as the
metallic conduit s. They can be ‘shaped ‘ by the use of an internal bending
spring and immersion in hot water.
The main advantage of PVC are its lightness and non-corrosive qualities
which makes PVC conduit ideally suitable for farm, horticultural and other
indoor and outdoor installation where corrosive substances are present and the
temperature does not exceed around 700C.
4.3.2 Measuring and cutting conduits
Measuring conduits
4.3.3 Bending of conduits
Bending Conduit Using Bending Machine
4.3.4 Fitting of conduits

4.4.2 Junction Box types and applications

Electrical codes require that all wire connections or cable splices be inside an approved
metal or plastic box. And every box must be accessible -- you cannot bury it inside a wall. This
protects your home from the danger of fire and makes it easier to inspect and upgrade your wiring in
the future.

Codes govern how many connections you're allowed to make within a

box, depending on its size. If you must make more connections, you
have to use a larger box (see the chart at the end of this section for
details).
Boxes for switches and receptacles serve as the workhorses in any electrical installation. Some of the
metal ones can be "ganged" into double, triple, or larger multiples by removing one side and linking
them together. Switch/receptacle boxes made of plastic are accepted by most codes, but they can't be
ganged. If you are using conduit, Greenfield, or BX, you must use metal boxes to ground the system.

Utility boxes are surface-mounted in basements and garages to hold switches or receptacles. Boxes
for fixtures or junctions may support lighting fixtures or split circuits into separate branches.
4.4.3 Application and working position of Junction box

Junction boxes are needed to install everything from outlets to ceiling fans.

An electrical box has one primary function-to house electrical connections. Those connections might
be to a switch, a receptacle, the leads of a light fixture, or other sets of wires.

There are boxes to suit most any depth of wall or ceiling, boxes to support heavy fixtures such as
ceiling fans, and boxes for remodeling work and new construction. If, for instance, you'll be pulling
cables through a finished wall, you can choose from a number of retrofit boxes that can be mounted
with a minimum of damage to the wall.

In this section, you'll read about some common box types and some important safety and code
considerations.

Ceiling rose with looping

and earth terminal

Junction boxes are needed to install tee connection, switches and socket outlet.
Junction box
When several cables have to be threaded at the same time two hands are needed. The illustration
shows the function of junction Box and method of gripping the cable so as to guide into the conduit
with the two forefingers
4.4.4 Conduit fixers & couplers

Conduit Couplers: Conduit is available in lengths from 3 m to 5 m and for straight

runs of greater length. Couplers are used to join two lengths of conduit. The lengths of the screwed
conduit are always threaded at both ends on the outer side.
Another method of coupling of light gauge conduit is by means of grip couplers. All conduits
joined by this method must be perfectly clean so that electrical continuity is not disturbed.
For coupling a flexible conduit to the rigid conduit, a combined coupling is used. The coupler
employed for this purpose has threaded hole on one side to receive threaded end of the conduit and
has a large hole to receive the flexible conduit on the other side.

Bends , Elbows and Tees: In general conduit fittings include bends , elbows and tees. All these can
be either of the inspection type (provided with the detachable lid ) or solid.
Bends are usually used for change in direction of conduit. These should never be sharp. The
minimum allowable radius of curvature is 2.5 times the outside diameter of the conduit.
Solid elbow and tees should be used only at the end of the conduit run ( e.g. close behind a
light fitting or accessory ) . The detachable lid provided in inspection type tees and elbows facilitate
pulling of cables.
Conduit Boxes: Conduit boxes are used in surface conduit wiring as well as concealed conduit
wiring. The conduit boxes are of different designs. These serve the following purposes:
1) For providing connections to light, fan and other points. The conduit boxes serving the
purpose are known as outlet boxes because conduit terminates at the boxes. These boxes
may have entry either from side or from back or from sides.
2) For pulling of cables into the conduits. The boxes serving this purpose are known as
inspection boxes. These are provided after every 30 m length of straight run.
3) For housing junction of cables. The conduit boxes serving this purpose are known as
junction boxes.

Types of fixing materials

Components and fixtures can be mounted on to wooden surfaces with wood screws. (Fig f1)
Wood screws cannot be screwed directly into a masonry surface because it is too hard and brittle.
(Fig f2)

Fig f1 Fig f2
Wall plugs are inserted into holes which are drilled into masonry surface.(Fig f3)

Fig f3 Fig f4
There are many types and sizes of wall plugs. They are made of plastic, fibre or lead and in
some cases, of soft wood.
 A. Plastic
B. Fiber
C. Fiber with metal sleeve

Fig f5 Fig f6
Wires, cables and conduits are fastened onto the installation surface with clips or saddles. (Fig f5)
Cables, which are used in industrial electrical installations, are fastened with saddles. They are
larger and stronger than clips. (Fig f6)

Use of Fixing Materials

Wires, cables and conduits are used in domestic and industrial electrical installations. They are

fastened onto installation surface with the fixing materials which we discussed before.
Electrical Fittings
Types of Electrical fittings.
Fittings are electrical element, which provides electricity to portable electrical appliance such as
lamps, TVS, fans and many others.

Socket outlet is one of the electrical fittings which provides power to electrical devices (fig ff)

fig ff2
Fig ff
Terminals and connectors are also another types of electrical fittings. (fig ff2)
Terminal Blocks used in industrial electrical installations to connect wires to each other.(fig ff3)
 Fig ff3

Use of electrical Fittings

Socket outlet is one of the electrical fittings, which is used for supplying power for portable
electrical devices such as TVS, Heater etc.
Terminals and connectors will provide electrical connection for electrical components.
Terminal Blocks in an electrical installation is used to connect wires to each other.
Review Questions
1. List two types of electrical fittings.
2. State is the use of terminal block.
3. State the use of terminals and connectors.

4.5 Insulators
Insulating materials have very high electrical resistance, so as to practically non conducting.
Current can only be passed through confined paths if conductors are insulated.
Conductors touching each other will make short circuit if insulation between them is removed.
Properties of Good Insulating Materials
1. High Specific resistance
2. Good dielectric strength.
3. Good Mechanical Strength.
4. Non-hygroscopic: this property enables the insulator not to absorb moisture.

Types of insulating Materials

Common Insulating Materials
Mica: - a mineral obtained in the form of sheets used as a dielectric of small capacitors in its pure
form.
Glass: - it is a good insulating material
Porcelain: - It is a good insulating material.
Paper: - It is also a good insulating material
Bakelite: - Many electrical accessories such as switches, lamp holders, wall sockets, plugs etc. are
made from bakelite.
Asbestos: - it is a fibrous material. Asbestos boards are raised for arc chutes, barriers, low
voltage terminal boards & supports. Oil, Poly vinyl chloride (Pvc), they are also a
good insulating material.

Most solid materials are classified as insulators because they offer very large resistance to the flow
of electric current. Metals are classified as conductors because their outer electrons are not tightly
bound, but in most materials even the outermost electrons are so tightly bound that there is
essentially zero electron flow through them with ordinary voltages. Some materials are particularly
good insulators and can be characterized by their high resistivities:

Resistivity (ohm m)
Glass 10^12
Mica 9 x 10^13
Quartz (fused) 5 x 10^16

This is compared to the resistivity of copper:

Resistivity (ohm m)
Copper 1.7 x 10^-8

Definition

An Insulator is a material or object, which resists the flow of heat (thermal

insulators) or electric charge (electrical insulators).

Electrical insulator

Insulated copper lamp wire

The term electrical insulator has the same meaning as the term dielectric, but the two terms are used
in different contexts.The opposite of electrical insulators are conductors and semiconductors, which
permit the flow of charge. Semiconductors are strictly speaking also insulators, since they prevent
the flow of electric charge at low temperatures, unless doped with atoms that release extra charges to
carry the current. However, some materials (such as silicon dioxide) are very nearly perfect electrical
insulators, which allow flash memory technology. A much larger class of materials, (for example
rubber and many plastics) are "good enough" insulators to be used for home and office wiring (into
the hundreds of volts) without noticeable loss of safety or efficiency.
High voltage insulators

High voltage insulators used for high voltage power transmission are either porcelain insulators or
composite insulators. Porcelain insulators are made from clay, quartz or alumina and feldspar.
Alumina insulators are used where high mechanical strength is a criterion. In recent times there is a
shift towards composite insulators which have a central rod made of fiber reinforced plastic and
outer weathersheds made of silicone rubber or EPDM. Glass insulators were, and in some places are
still used to mount electrical power lines. Most insulator manufacturers stopped making glass
insulators in the late 1960's, switching to ceramic materials. Composite insulators are less costly,
light weight and have excellent hydrophobic capability and hence can be used in polluted areas.

Low voltage insulators

Insulating materials such as PVC (polyvinyl chloride) are used to minimize the possibility of a
person coming into contact with a 'live' wire. Some appliances such as electric shavers and hair
dryers are doubly insulated to protect the user. They can be recognized because their leads have two
pins, or on 3 pin plugs the third (earth) pin is made of plastic rather than metal. In the EU, double
insulated appliances all are marked with a symbol of 2 squares, one inside the other.

Double insulation requires that cables have basic and supplementary insulation, each of which is
sufficient to prevent electric shock. Usually, the internal electrical components are totally enclosed in
an insulated packaging which prevents any contact with live parts.

Thermal insulators

A perfect thermal insulator is impossible to achieve due to the second law of thermodynamics.
Among naturally occurring substances, mica and asbestos have performed well as both thermal and
electrical insulators, until the advent of better synthetic (man-made or man-modified) products.

See also: insulation

Polyvinyl chloride (PVC) is a widely-used plastic. In terms of revenue generated, it is one of the
most valuable products of the chemical industry. Globally, over 50% of PVC manufactured is used
in construction. As a building material, PVC is cheap and easy to assemble. In recent years, PVC has
been replacing traditional building materials such as wood, concrete and clay in many areas. Despite
appearing to be an ideal building material, concerns have been raised about the environmental and
human health costsofPVC.

There are many uses for PVC including vinyl siding, plastic cards (Credit, ID, etc...),window
profiles, gramophone records (hence the ones made of this material are sometimes called vinyl
records), pipe/plumbing/conduit fixtures, bean bags; and, in its soft form, for clothing, upholstery
(car seats), flooring, roofing membranes, electrical cables, etc. The material is often used for
pipelines in the water and sewer industries of its inexpensive nature and flexibility.
INSULATION COLOR CODE
The insulation on conductor is colored to make the electrician jobs easier. If you
understand and follow the color code system, joining and connecting wires is easier and
quicker, and wiring errors are much less likely to happen.

The insulation colors generally used in the trades are as follows

1. two conductor cable contains one white wire, one black wire and a ground wire.
2. three conductor cable contains one white wire, one black wire, one red wire, and a
grounding wire.
3. four and five conductor cables are available, but are rarely used in home wiring. In
these cables the fourth conductor is blue and the fifth is yellow.
The grounding wire in all of these cables is usually a bare wire, but it may have
either green or green with yellow strip insulation.

Fig. ll Insulation color codes

Use of insulating Materials
The main components of every electrical machine and equipment are the conductors and insulators.

Mica: - is used as a dielectric of small capacitors in its pure form.

Glass: - Used for insulators of overhead lines & for winding insulation.
Porcelain: - widely used for insulators of overhead lines, fuse carriers etc.
Paper: - used as capacitor dielectric.
Bakelite: is used to prepare boards to mount electrical equipment.
Asbestos: is used for covering conductors of hot places. They are also used for covering
conductors.
Oil: - it is used to insulate and cool transformer or circuit
5. Reading Installation Plan

5.1 Electrical Symbols and standards

Need of Electrical Symbols

STANDARD ELECTRICAL QUANTITY SYMBOLS AND THEIR UNITS
LAYING OUT
Every thing presented here involves concealed wiring, hidden in the
walls or in the other parts of a house. Depending on your situation, as an option,
you might consider using surface wiring, an easier type to install because it is run
on baseboards or on the surfaces of walls in the ceilings.
Running cable along the basement joints
Running cable to an attic and behind a plasterboard wall
Running cable to a ceiling for a new light and switch
Running cable to a ceiling for a new light and switch (continued)
i) Running cable behind a baseboard ii) Running cable for back to back boxes
 i) Running cable to a ceiling with access from an adjacent room
ii) running cable around doorways
ASSESSMENT QUESTION
i) What are the differences between concealed and surface
wiring?
ii) Which type of wiring system is easier to install?