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  1. 1 | P a g e Industrial Electrician Table of Contents 1.0 General safety and electrical safety...................................................................3 1.1 Lifting and handling safety...............................................................................................3 1.2 General safety of tools and equipments..........................................................................3 1.3 Electrical safety................................................................................................................6 1.4 Handling electrical fires ...................................................................................................7 1.5 First aid treatment of electrocuted person .....................................................................9 1.6 Safety permits applicable to electrical department ......................................................12 2.0 Basics of Electricity..........................................................................................15 2.1 Basic terms used in electrical technology......................................................................15 2.2 Hand tools used in electrical applications .....................................................................22 2.3 Electrical accessories used in industrial wiring..............................................................32 3.0 Electrical Circuits.............................................................................................43 3.1 Types of wires and conductors, load carrying capacity.................................................43 3.2 Wiring diagrams.............................................................................................................47 3.3 Conductors and insulators.............................................................................................55 3.4 Concepts of AC, DC, single phase and 3 phase supply...................................................57 3.5 OHMS law.......................................................................................................................63 3.6 Measurement of current, voltage & power...................................................................65 3.7 Series and parallel circuit...............................................................................................70 3.8 Fuses and MCB...............................................................................................................73 4.0 Electrical Wire.................................................................................................82 4.1 Wire gauge.....................................................................................................................82 4.2 Skinning of cables..........................................................................................................82 4.3 Types of joints................................................................................................................83 4.4 Crimping.........................................................................................................................87 4.5 Soldering ........................................................................................................................89 5.0 Wiring and testing of circuits...........................................................................91 5.1 Electrical accessories/fittings.........................................................................................91 5.2 Earthing..........................................................................................................................98 5.3 Types of faults in electrical circuits................................................................................99 5.4 Quality assurance in electrical works...........................................................................103 5.5 Energy saving concepts................................................................................................106 6.0 IE rules..........................................................................................................110 6.1 IE rules..........................................................................................................................110
  2. 2 | P a g e Industrial Electrician 7.0 Motors..........................................................................................................117 7.1 Types of motors ...........................................................................................................117 7.2 Working principle of single phase and 3 phase induction motor................................123 7.3 Difference between squirrel case and slip ring induction motor................................124 7.5 Working principle of DOL, star delta starter and advantage.......................................126 7.6 Methods of speed control in motors...........................................................................132 7.7 Drives ...........................................................................................................................132 7.8 Tagging/identification procedures used in industries .................................................132 8.0 Transformers ................................................................................................ 135 8.1 Basic principle of transformer......................................................................................135 8.2 Types of transformers..................................................................................................135 8.3 Protective devices of transformers..............................................................................139 8.3 Various parts of transformers......................................................................................144 8.4 BDV test......................................................................................................................145 9.0 Motor Winding ............................................................................................. 146 9.1 Types of winding ..........................................................................................................146 9.2 Dismantling and re-winding an AC machine................................................................147 9.3 Insulating materials......................................................................................................150 9.4 Preparation of a winding data for a given motor ........................................................152 9.5 Testing procedure after rewinding ..............................................................................153 10.0 Transformer Winding .................................................................................. 158 10.1 Testing a transformer................................................................................................158 10.2 Measuring a enameled winding wire with wire gauge..............................................160 10.3 Steps in winding / rewinding a transformer..............................................................161 11.0 DG Set.........................................................................................................165 11.1 Function of DG set .....................................................................................................165 11.2 Various parts of DG set ..............................................................................................168 11.3 Connection and load distribution ..............................................................................168 12.0 Maintenance............................................................................................... 173 12.1 Panel cleaning methods.............................................................................................173 12.2 Major electrical breakdowns and preventive maintenance......................................174 12.3 Maintaining power ratio............................................................................................177
  3. 3 | P a g e Industrial Electrician 1.0 General safety and electrical safety OBJECTIVES: It is to explain trainees, what is the safety measures have to be taken during working in field. 1.1 LIFTING AND HANDLING SAFETY 1. Switch 'off ' the motor and remove the fuse carriers. 2. Ensure the equipment is disconnected from supply and the base plate nuts of the motor have been removed. 3. Make sure of the position where the equipment is to be placed. 4. Assess whether you need any assistance to carry the equipment. 5. Check for clear route path and the location for placement. Remove obstacles, if any. 6. Position yourself near the equipment for lifting. 7. Lift the equipment from the floor using the correct posture. 8. Carry the equipment to the work bench safely, keeping the equipment close to the body. 9. Keep the equipment carefully on the bench, and adjust its position correctly. Assume the over-hauling work is over and the motor to be placed in its original place. 10. Lift the equipment correctly with a firm grip. 11. Carry the equipment to the original place. 12. Lower the equipment safely with your feet apart, knees bent, back straight and arms close to your body. 13. Place the equipment safely on the floor. 1.2 GENERAL SAFETY OF TOOLS AND EQUIPMENTS The following procedures will prevent the human body from contact with electrical conductors, wiring, electrical sources, etc.
  4. 4 | P a g e Industrial Electrician Protective measures Insulation Shield the electrical conductor with an insulator to prevent direct contact Obstacles Place obstacles to prevent any accidental contact with the electrical conductor Barriers or enclosures Create barriers or enclosures that prevent any direct contact with the electrical conductor Placing out of reach This prevents accidental contact with the electrical conductor. Fuse Normally, a fuse is a copper wiring with a set current fusion value. If the current exceeds the set fusion value, the fuse will blow and the current is cut-off, thus preventing overloading. A fuse must be installed on "live" wires. When replacing a fuse, the new fuse must be of the same current fusion value. Circuit breakers (MCB) Circuit breakers are based on the principle of the electromagnetic field. The current entered may enable the coils of the circuit breaker to magnetize. When the current exceeds the set value (i.e., overloading), the magnetization intensifies, switching off the circuit breaker and disconnecting the electric source. Earthing Earthing provides a low resistance way of discharging electricity to the ground in case of current leakage. This means that during an electric shock, the current passes through the "earth" wire and is prevented from entering the human body and causing injury.
  5. 5 | P a g e Industrial Electrician Apart from the above the following other safety tools also used in workshop Arc Flash Protective Clothing Arc and Flash Fire Resistant Rainwear DBI Sala arc flash harnesses, lanyards, kits, SRL's Insulating Gloves, Kits, Accessories Insulating Blankets, Roll Blankets, Aprons, Accessories Electrical Switchboard Matting Arc Protection Blankets Dielectric Footwear Hot Sticks, FRP Clamp Sticks - Shot-gun Sticks Static Discharge Sticks Insulated Rescue Sticks / Hooks Grounding Equipment and Sets
  6. 6 | P a g e Industrial Electrician 1.3 ELECTRICAL SAFETY  Never work in wet/damp places without proper safety.  Do not put any metallic articles like finger rings, bracelets or any other jewellery on your body while working on electric supply.  Use insulated rubber sole shoes while working.  Do not work without any footwear. Do not use chapels.  The stairs used while working should be sturdy and safe. An assistant should be working with you.  All tools used should be properly insulated and in good working condition.
  7. 7 | P a g e Industrial Electrician  Always use insulated gloves while working on high voltage electric supply.  Avoid working on live parts. Switch off supply before working. 1.4 HANDLING ELECTRICAL FIRES All fires are dangerous. They cause damage to property and loss of human lives. Electric fires are particularly dangerous. An electrician will be required to handle electrical fires. He must be smart, quick acting and fast in decision making to save damages of any kind. Sources of electrical fire The main causes of electric fire are: 1. Loose connections The loose connection cause sparking which ultimately result in fire. The electrician must ensure that all the connections are tight and safe. 2. Overload If the current carries more current than what it is designed for, it may lead to fire. The ratings of the equipment connected in a circuit should be kept in mind. 3. Use of incorrect rating of fuses Great care should be taken in selection of fuses. Wrong selection of fuses can be dangerous. 4. Short circuits Short circuits occur due to failure of insulation, overheating, and use of poor quality of cables. Extinguishing the fire The basic reason of growth of fire should be understood. The three things Fuel, Oxygen and Heat together are responsible for fire. Whenever, the supply of any one, or, all the 3 is stopped, the fire will be extinguished. You should keep this in mind, whenever the fire is to be extinguished. The fires are classified under categories A,B,C, D and E for different types of fires. Ensure that
  8. 8 | P a g e Industrial Electrician the extinguisher, you are using is suitable for electrical fire. It will be written on the Fire extinguisher. Carbon dioxide, dry power and vaporizing liquid (CTC) extinguishers can be used to deal with electric fires. Caution: Foam or liquid (water) extinguishers must not be used to quench electric fires. It can be dangerous and user can get shock. Always read and understand the operating instructions before using a Fire extinguisher. General procedure to be adopted in the event of fire 1. Raise an alarm. Follow the method written below for giving an alarm signals when fire breaks out. By raising your voice and shouting Fire! Fire! To call the attention of others running towards fire alarm/bell to actuate it other means. 2. On receipt of the alarm signal, Stop working, Turn off all machinery and power; Switch off fans/air circulators/exhaust fans. (Better switch off the main.) 3. If you are not involved in fighting the fire: Leave calmly using the emergency exit. Evacuate the premises, Assemble at a safe place along with the others, Check if anyone has gone to inform about the fire break to the concerned authority, Close the doors and windows, but do not lock or bolt In case of fire:  Do not panic. Be calm.  Switch off the electric supply immediately.  Raise an alarm to let others know about the accident.  Evacuate persons from the area of safety.  Use Fire extinguishers as advised in Operating instructions.
  9. 9 | P a g e Industrial Electrician 4. If you are involved in fire fighting: Take instructions/give instructions for an organized way of fighting the fire. If taking instructions: Follow the instructions, and obey, if you can do so safely; do not risk getting trapped. If giving instructions: Assess the class of fire, Send for sufficient assistance and inform the fire brigade, Locate locally available suitable means to put out the fire. Judge the magnitude of the fire; ensure emergency exit paths are clear of obstructions and then attempt to evacuate (Remove explosive materials, substances that can serve as a ready fuel for fire within the vicinity of the fire break.). Fight out the fire with assistance to put it out, by naming the person responsible for each activity. 5. Report the fire accident and the measures taken to put out the fire, to the authorities concerned. Reporting all fires however small helps in the investigation of the cause of the fire. It helps to prevent the same kind of accident occurring again. 1.5 FIRST AID TREATMENT OF ELECTROCUTED PERSON Electric shock: The severity of an electric shock will depend on the level of the current which passes through the body and the length of time of the contact. Other factors that contribute to the severity of shock are:  age of the person  not wearing insulating foot weal or wearing wet footwear  weather condition  Mains voltage etc. Effects of electric shock: The effect of current at very low levels may only be an unpleasant tingling sensation, but this in itself may be sufficient to cause one to lose his balance and fall. At higher levels of current, the person receiving the shock may be thrown off his feet and will experience severe pain, and possibly minor burns at the point of contact. An excessive level of current flow, the muscles may contract and the person unable to release his grip on the conductor. He may lose consciousness and the muscles of the heart may contract spasmodically (fibrillation). This may be fatal. Electric shock can also cause burning of the skin at the point of contact.
  10. 10 | P a g e Industrial Electrician Treatment of electric shock Prompt treatment is essential. If assistance is close at hand, send for medical aid, then carry on with emergency treatment. If you are alone, proceed with treatment at once. Switch off the current, if this can be done without undue delay. Otherwise, remove the victim from contact with the live conductor, using dry non-conducting materials such as a wooden bar, rope, a scarf, the victim's coattails, any dry article of clothing, a belt, rolled-up newspaper, non-metallic hose, PVC tubing, bakelised paper, tube etc. Avoid direct contact with the victim. Wrap your hands in dry material if rubber gloves are not available. Electrical burns: A person receiving an electric shock may also sustain burns when the current passes through his body. Do not waste time by applying first aid to the burns until breathing has been restored and the patient can breathe normally - unaided. Burns and scalds: Burns are very painful. If a large area of the body is burnt, give no treatment, except to exclude the air, e.g. covering with water, clean paper, or a clean shirt. This relieves the pain. Severe bleeding: Any wound which is bleeding profusely, especially in the wrist, hand or fingers must be considered serious and must receive professional attention. As an immediate first aid measure, pressure on the wound itself is too best means of stopping the bleeding and avoiding infection. Immediate action: Always in cases of severe bleeding:  make the patient lie down and rest  if possible, raise the injured part above the level of the body (Fig)  apply pressure to the wound  Summon assistance.
  11. 11 | P a g e Industrial Electrician Control severe bleeding: Squeeze together the sides of the wound. Apply pressure as long as it is necessary to stop the bleeding. When the bleeding has stopped, put a dressing over the wound, and cover it with a pad of soft material. (Fig) For an abdominal stab wound, such as may be caused by falling on a sharp tool, keeps the patient bending over the wound to stop internal bleeding. Large wound: Apply a clean pad (preferably an individual dressing) and bandage firmly in place. If bleeding is very severe apply more than one dressing. (Fig) Follow the right methods of artificial respiration.  Remove the victim from contact with the live equipment.  Tight clothing which may interfere with the victim's breathing must be loosened.  Remove any foreign materials or false teeth from his mouth, and keep the mouth open.  Do not delay artificial respiration for loosening clothes or even if the mouth is closed tightly  Nelson's arm-lift back pressure method must not be used in case there are injuries to the chest and belly.  Place the victim prone (that is, face down) with his arms folded with the palms one over the other and the head resting on his cheek over the palms. Kneel on one or both knees near the victim's hand. Place your hands on the victim's back beyond the line of the armpits, with your fingers spread outwards and downwards, thumbs just touching each other as in Fig.  Gently rock forward keeping the arms straight until they are nearly vertical, and thus steadily pressing the victim's back as in Fig to force the air out of the victim's lungs.
  12. 12 | P a g e Industrial Electrician  Synchronizing the above movement rock backwards, slide your hands downwards along the victim's arms and grasp his upper arm just above the elbows as shown in Fig. Continue to rock backwards.  As you rock back, gently raise and pull the victim's arms towards you as in Fig until you feel tension in his shoulders. To complete the cycle, lower the victim's arms and move your hands up to the initial position. Other steps 1. Send for a doctor immediately. 2. Continue artificial respirations till the victim begins to breathe naturally. Please note in some cases it may take hours. 3. Keep the victim warm with a blanket, wrapped up hot water bottles or warm bricks; stimulate circulation by stroking the insides of the arms and legs towards the heart. 4. When the victim revives, keep him lying down and do not let him exert himself. 5. Do not give him any stimulant until he is fully 1.6 SAFETY PERMITS APPLICABLE TO ELECTRICAL DEPARTMENT  Only qualified persons should do electrical work.  Keep the workshop floor clean and tools in good condition.  Do not work on live circuits; if unavoidable, use rubber gloves rubber mats, etc.  Use wooden or PVC insulated handle screwdrivers when working on electrical circuits.  Do not touch bare conductors  When soldering, arrange the hot soldering irons in their stand. Never lay switched 'ON' or heated soldering iron on a bench or table as it may cause a fire to break out.
  13. 13 | P a g e Industrial Electrician  Use only correct capacity fuses in the circuit. If the capacity is less it will blow out when the load is connected. If the capacity is large, it gives no protection and allows excess current to flow and endangers men and machines, resulting in loss of money.  Replace or remove fuses only after switching off the circuit switches.  Use extension cords with lamp guards to protect lamps against breakage and to avoid combustible material coming in contact with hot bulbs. Use accessories like sockets, plugs and switches and appliances only when they are in good condition and be sure they have the mark of BIS marked accessories is explained under standardization.  Never extend electrical circuits by using temporary wiring.  Stand on a wooden stool or an insulated ladder while repairing live electrical circuits/ appliances or replacing fused bulbs. In all the cases, it is always good to open the main switch and make the circuit dead.  Stand on rubber mats while working/operating switch panels, control gears etc.  Position the ladder, on firm ground.  While using a ladder, ask the helper to hold the ladder against any possible slipping.  Always use safety belts while working on poles or high rise points.  Never place your hands on any moving part of rotating machine and never work around moving shafts or pulleys of motor or generator with loose shirt sleeves or dangling neck ties.  Only after identifying the procedure of operation, operate any machine or apparatus.  Run cables or cords through wooden partitions or floor after inserting insulating porcelain tubes.  Connections in the electrical apparatus should be tight. Loosely connected cables will heat up and end in fire hazards.  Use always earth connection for all electrical appliances along with 3-pin sockets and plugs.  While working on dead circuits remove the fuse grips; keep them under safe custody and also display 'Men on line' board on the switchboard.  Do not meddle with interlocks of machines/switch gears.  Do not connect earthing to the water pipe lines.  Do not use water on electrical equipment.  Discharge static voltage in HV lines/equipment and capacitors before working on them.
  14. 14 | P a g e Industrial Electrician ASSIGNMENTS 1. What Safety precaution would you observe to avoid electrical accidents? 2. What Safety points would you observe during shifting? 3. What is Artificial respiration? 4. What you do during event of fire? 5. Safety of wire depends upon what? 6. What is the role of fuse? 7. What is MCB? 8. MCB works on which principle? 9. Earthing is necessary, why? 10. What is prompt treatment? 11. What are fire extinguishers? 12. How heavy equipment shifted from one place to another place? 13. How artificial respiration done for a person who is getting shock?
  15. 15 | P a g e Industrial Electrician 2.0 Basics of Electricity OBJECTIVES: This is to understand and remember the basics of electricity. 2.1 BASIC TERMS USED IN ELECTRICAL TECHNOLOGY The terms you are required to know are: Volt, ampere (amp), watt, ohm, resistance, potential difference, rectifier, rheostat, conductor, ground, circuit, and short circuit. The others in here are good to know. Electron Electrons are tiny negatively charged particles that orbit the positively charged nucleus of atoms. Electrons are so small that they only account for a very small portion of the overall mass of the atom. To get a better idea of what's going on; see the Bohr model for Aluminum to the right. The number of protons in an atom (in this case, 13) indicates the atomic number of an atom. The interaction of electrons between atoms allows the formation of chemical bonds. Current flow through a circuit is these electrons jumping from atom to atom at about the speed of light. When an atom looses or gains an electron, the atom no longer has a neutral charge becomes ionized. Here is an example Potential Difference The difference in electrical potential, or voltage, from one point in a circuit to another. The voltage rating on a battery describes the potential difference between its terminals. Regardless of the potential in circuit, there can be no current flow until the terminals are connected, or there is enough energy to overcome a barrier (like air) and electrons are allowed to flow from one terminal to another. So, if you have a 10,000 volt battery, and it's not connected to anything, there will be no current flow-- but as soon as you touch both terminals you'll get a nasty surprise.
  16. 16 | P a g e Industrial Electrician Volt (V) Voltage a unit of measure is the driving force, or potential difference behind electron flow, and hence the force behind the flow of current in an electrical circuit.  Voltage is a measure of the energy carried by the charge. Strictly: voltage is the "energy per unit charge".  The proper name for voltage is potential difference or P.D. for short, but this term is rarely used in electronics.  Voltage is supplied by the battery (or power supply).  Voltage is used up in components, but not in wires.  We say voltage across a component.  Voltage is measured in volts, V.  Voltage is measured with a voltmeter, connected in parallel.  The symbol V is used for voltage in equations. Resistance The resistance of a circuit to the flow of electrons, or current flow. Everything has some resistance associated with it, even metal wires. Some of these resistances are so small that we will ignore them in most cases. Heat changes the resistance of all materials. Some materials will increase their resistance as they get hotter, others will decrease their resistance. This property of materials can be used to make electronic circuits that can measure heat. Ohm (Ω) The unit of measure for a circuit’s resistance to current flow. Resistor Resistors have resistance, and their primary function is to add resistance to a circuit. The electrical symbol for a resistor is . Below is a picture of what some resistors look like. The large white one is a power resistor. Power resistors can handle a lot of current flow without burning up. The color bands indicate the resistance; the color of the body indicates the type of resistor (carbon, wire, and so on). The tan resistors are carbon resistors. Current The flow of electrons in a circuit, measured in Amps. Current, I  Current is the rate of flow of charge.
  17. 17 | P a g e Industrial Electrician  Current is not used up, what flows into a component must flow out.  We say current through a component.  Current is measured in amps (amperes), A.  Current is measured with an ammeter, connected in series. To connect in series you must break the circuit and put the ammeter across the gap, as shown in the diagram.  The symbol I is used for current in equations. Direct Current (DC) Direct current sources never have current flowing in the opposite direction, that is, the positive and negative sides never reverse. A battery only produces direct current when connected to a circuit (the circuit can change the DC into AC). Alternating Current (AC) Alternating current means the current flow goes one way and then reverses its direction at regular time interval. This happens because one terminal is negative and the other is positive for a while, then they switch from being negative to positive and from positive to negative. In India frequency of AC is 50 HZ. A person that has been shocked for by AC should be watched for a few hours to make sure he doesn't have a heart attack. Battery Batteries convert chemical energy into electrical energy. Multiple battery cells can be connected in series to increase the voltage of the circuit. All batteries have some internal resistance, which means some batteries are better at high current flows than others. The plus sign isn't always there. The longer end indicates the positive terminal, and the smaller one is the negative terminal. Some electrical drawings have several of these battery cell symbols staked on each other. This means it's a battery pack, or just a battery. Current Flow and Electron Flow Both terms essentially mean the same thing when talking about an electrical circuit: electrons moving from one place in a circuit to another. The direction of current flow was
  18. 18 | P a g e Industrial Electrician determined by Benjamin Franklin, who said that current flows from the positive to negative. Well, he had a 50% chance of getting that right and just missed it. Electrons really flow from the negative terminal to the positive terminal. When we talk about Current Flow we assume that current flows from positive to negative. When we talk about Electron Flow, we assume that current flows from negative to positive (which is really the case). When working with circuits, it makes little difference if you use electron or current flow. Since most books use current flow, rather than electron flow (which is a newer term), that is what we will be using. When we start talking about what happens inside of semiconductors (transistors, diodes, etc), we have to talk about electron flow within that component to understand what is going on inside. But Electron Flow is what's really happening in a circuit on a subatomic level. When we talk about AC, the direction of current changes constantly, so we just pick a direction and sick with it when performing circuit analysis. Conductor A material in which current is able to flow through easily. Most metals make good conductors, some better than others, silver being the best in normal conditions. Super- conductors have nearly no resistance to current flow, but they often have to be super- cooled to work and are very expensive. Semiconductor These materials can either be good conductors or good insulators, or somewhere in between, based on certain conditions. They are used in diodes, transistors, and other electrical components. They are very useful and are the reason why we have the computers we have today. The most common base material used in semiconductors is Silicon (Si), the second is Germanium (Ge). Germanium semiconductor components take away less of the electron's energy than Silicon, but are more expensive. Silicon is refined from beach sand. Insulator a material that does not conduct current very well. It is the exact opposite of a conductor. The rubber around wires is an insulator. Glass is also used as an insulator. Watt (W) The measurement of power in a circuit, as determined by multiplying volts times amps: P=V x I A Kilowatt is 1,000 watts. A Watt-Hour is the number of watts used over an hour. You can think of Watt as measuring the speed you're using power, like MPH (miles per hour), and a Watt-hour as the distance you've actually traveled over that time. Using Ohms Law, by
  19. 19 | P a g e Industrial Electrician substituting V for I x R we get P=R x I2 . We will use this equation when talking about why the power companies step up line voltage to insane values in transmission lines, and later step it back down to household values. Short Circuit Current wants to take the path of least resistance. If there is a path of very low resistance, current will want to flow that direction more than any other. When there is a path of very low resistance back to the power source (which isn't supposed to be there), we call this a short circuit. A short circuit can cause a fire. Fuse A fuse is a device that, if a current level is exceeded, the wire, or substance inside of the fuse, will heat up and then melt, breaking the electrical connection. There are fast and slow blow fuses. Fast blow fuses are used to protect circuits from short circuit conditions. Slow blow fuses don't blow right away when they have reached their current rating. Slow blow fuses are used with motors and other components that have high starting currents. Circuit Breaker A Circuit Breaker provides overload protection. They are slower acting than a fuse. Circuit breakers are electro-mechanical devices (which mean they are part electrical and part mechanical) which will break a circuit if too much current is flowing through a circuit for too long. Rheostat/Potentiometer A Rheostat is similar to a resistor, except that the resistance of the component can be changed by turning a knob or moving a slider (slide-type rheostats are used on sound mixing boards). That is why the electrical symbol looks like a resistor with an arrow through it. That line means that it can be adjusted. You'll see something similar on other devices that can be adjusted by a knob, such as capacitors and inductors. Generator A device that generates electron flow through moving a conductor through a magnetic field. The amount of voltage induced in the generator coil is directly proportional to the strength of the magnetic field, and the speed at which the magnetic field is changing or moving through the conductor.
  20. 20 | P a g e Industrial Electrician Transformer Transformers are able to step up, or step down AC voltages through magnetic field interactions. They are also able to isolate an AC circuit form other AC circuits. AC current causes the magnetic field to continually grow, decrease, and then increase over and over again. This produces a moving magnetic field Just like what's needed to make a generator work. To the right is a diagram of a transformer. To the left is the electrical symbol for a transformer. Rectifier A device that converts AC into DC. Diodes are used to rectify a AC into DC because they allow current to flow only in one direction. In order to produce a clean DC output, filters have to be used. Usually capacitors are used in these filters. Another method that is used to convert AC to DC is the use of a motor-generator set. AC motor is used to spin a DC generator. It's not as efficient as using a rectifier, but they are cheaper for large current applications and are used on some older elevator systems. Ground Ground is considered at zero potential. There are two types of grounds: a circuit or chase ground, and an earth ground. An earth ground means that the ground is somehow physically connected to the ground you’re standing on. A circuit or chase ground just means that there is a wire or connection that is connected to the case that the circuit is housed in. The earth ground is often connected to the metal case of the machine. Electricity takes the path of least resistance, so, if there is a good earth ground to a metal case, electricity would rather flow through the grounding wire instead of you. The grounding wire in a house is either green or bare copper. If you don't have three prong outlets in your house, you need to have a licensed electrician come out and rewire your house. He'll also put in a device called a GFCI, or Ground Fault Interrupter. GFCI's will break the circuit if there is a ground fault-- like what would happen if you drop something electrical in a tub.
  21. 21 | P a g e Industrial Electrician Inductor An inductor is a coil of wire, any coil of wire is actually an inductor. Inductors, by themselves, tend to resist a change in current flow. They store energy in the magnetic field produced by current moving through a conductor. When current flow begins to slow, the magnetic field begins to collapse, and thus induces a voltage in the coil that increases current flow. There are a few applications for inductors, such as used in filters. Motors are also inductors, and, next to transformers, are the largest inductors in an electrical circuit. Cutting off power to these circuits can cause a large voltage spike which is called an "inductive kick." Capacitors are used to suppress this inductive kick by counteracting the effect of the inductor. Capacitor A device that resists changes in voltage. It stores electrons between metal plates and an insulator. They are used in filters, and power supplies to maintain voltage during current surges. They also cancel out the effect of inductors in AC circuits and suppress the "inductive kick" in both AC and DC circuits. Capacitors come in many shapes and sizes. Diode Diodes were the first semiconductor component developed. They only allow current to flow in one direction. They find uses in many places, and are the main components of rectifiers. A minimum voltage is required in order for a diode to pass current through it. Here is what they look like: Lamp/Light Bulb Basic incandescent light. It produces light by heating up a special wire, called a filament, which then glows. The element that is commonly used in light bulbs is Tungsten, because it begins to glow well before it reaches its melting point. The mantels in gas lanterns now use tungsten for the same reason (they used to use Thorium, which is radioactive, but stopped in the 1980s). LED (Light Emitting Diode) LEDs are special diodes that, when current passes through them, they will light up. They use far less power than a lamp, and last far longer. The little arrows are supposed to show photons, or light, being emitted. Resistors are often needed with LEDs to lower the current flow through the LED to a safe value (dependent on the LED, but around 10-30 milliamps is usually good). Different color LEDs require different minimum voltages to turn on.
  22. 22 | P a g e Industrial Electrician 2.2 HAND TOOLS USED IN ELECTRICAL APPLICATIONS There are innumerable types of hand tools used for different types of work. Some of the basic tools which are a must for mechanic electronics are dealing in:  screwdrivers  pliers, and  Tweezers. Screwdrivers A screwdriver is a tool used to tighten or loosen screws. A simple screwdriver and its parts are shown in Fig. When a screwdriver is used to tighten or loosen screws. The blade axis of a screwdriver must be linked up with that of the screw axis as shown in Fig 2. Length of blade L and Length of tip W Normally there is no relationship between the length of the blade and the width of the tip of a screwdriver. A screwdriver with a 6 mm wide tip can have blade lengths ranging from 25 to 250 mm. It can also have various forms of handles as shown in Fig 10.
  23. 23 | P a g e Industrial Electrician There are, however, screwdrivers which are made to an industrial specification such as DIN, ISI etc. These screw-drivers have fixed dimensions and for each size of screwdriver the width of its tip and the length of its blade are specified as shown in Fig 11. Fig 12 shows a Phillips cross-type screwdriver tip. It is used to tighten and loosen screws with a Phillips cross type recess. Fig 13 shows a POZIDRIV CROSS TYPE screw driver tip. It is an improved type of a cross type tip. It has straight wings compared to the slightly tapered wings of the Phillips type tip. The straight wings keep the tip in the recess when turning force is applied to the screwdriver. Straight wings and Tapered wings The above cross type screwdriver tips are available in five standard sizes, numbers 0, 1, 2, 3 and 4 as shown in Fig 14. These five sizes of tips are used for all screws with cross type recesses from M2 to M12.7. Screwdrivers with cross type tips are also available with short blades ranging in lengths from 25 to 40 mm and with various forms of handles as shown in Fig 15. To show the difference between the screwdrivers with short and long blades a '0' is placed in front of the tip number of the short version. A few examples of other types of screwdriver tips for screw heads with
  24. 24 | P a g e Industrial Electrician various forms of recesses are shown in Fig 16. 1. Hexagonal socket head 2. Spine socket head 3. Clutch socket head 4. Slab socket head Never use the wrong type or size of a screwdriver as this will damage the recess of a screw head. If in doubt, ask your instructor/ask an experienced person to tell you which tip should be used. Instrument screwdrivers Fig 17 shows an INSTRUMENT SCREWDRIVER. It is used to turn very small screws as used in instruments, watches and clocks. It has a rotating head which is held by the forefinger, while the thumb and the middle finger are used to turn the screwdriver. Instrument screwdrivers are available in sets comprising 5 to 8 screwdrivers with the dimensions as given in the Table. Large screws can be turned easily by using screwdriver bits that fit into a carpenter brace. Such bits are available in different types and sizes of tips. Fig 18 shows a screwdriver with INTERCHANGEABLE TIPS. Such screwdrivers are available in sets comprising one handle with a universal fitting and an assortment of tips in various shapes and sizes. Impact screwdrivers Fig 19 shows an IMPACT SCREWDRIVER. It is used to tighten screws or loosen very tight screws. When the end of its handle is struck by a hammer, a powerful turning force is applied to the screw. Impact screwdrivers consist of a metal handle which
  25. 25 | P a g e Industrial Electrician can be used with a variety of exchangeable tips to suit different screw heads as shown in Fig 20. Fig -20 Screwdrivers for electrical work have fully insulated plastic or rubber handles. The handles are cast around the blades. Screwdrivers for heavy mechanical work often have blades which extend through the handle as shown in Fig 21 b. Such screwdrivers can be struck by a hammer in certain circumstances. Screwdrivers for electrical work often have insulated blades in the form of plastic sleeves which are fitted up to the tip of the blades as shown in Fig 22. Special types of screwdrivers Fig 23 shows a flat screwdriver tip with two prongs. It is used with screws having two rectangular recesses or with slotted nuts. It is available in various sizes suitable for screws and nuts ranging from M3 to M12. Fig 24 shows a flat screwdriver tip with two round pins. It is used with screws and nuts having two round recesses which accommodate the pins. It is also avail- able in a number of sizes for screws and nuts ranging from M3 to M12.
  26. 26 | P a g e Industrial Electrician Using a screwdriver The general procedure for using a screwdriver is given below.  Select a suitable screwdriver having the required blade length, width of tip and thickness of tip.  Check that the tip of the screwdriver is flat and square. Worn out tips tend to slip off while turning and may cause injury.  Make sure your hands and the screwdriver handle are dry and free from grease.  Hold the screwdriver with the axis in line with the axis of the screw.  Guide the blade with one hand as shown in Fig 23. Set the tip of the screwdriver in the screw slot.  Be sure of the direction in which the screwdriver is to be twisted. Twist the handle gently and steadily. Do not apply too much pressure in the axial direction of the screw. This may damage the screw threads. Never try to use a screwdriver as a lever; this could break the tip or bend the blade and make the screwdriver unusable. Pliers Pliers are tools which are used for:  holding, gripping, pulling and turning small parts and components,  shaping and bending light sheet metal parts,  Forming, bending, twisting and cutting small diameter wires. Pliers consist basically of a pair of LEGS which are joined by a PIVOT as shown in Fig 25. Each leg consists of a long HANDLE and a short JAW. If the legs of the pliers are crossed at the pivot, the jaws will CLOSE when pressure is applied to the handles as shown in Fig 25b. In some pliers the jaws will close when pressure is applied to the handles as shown in Fig 25c. Pliers have SERRATED or PLAIN JAWS as shown in Fig 26. Surrogated jaws offer a better grip on the work piece. Serrated jaws might, however, damage the surface of the work piece. In this case protection sleeves or pliers with non-serrated jaws as shown in Fig 26b should be used.
  27. 27 | P a g e Industrial Electrician Pliers are made from high quality steel. In many cases pliers are CHROMIUM PLATED to protect them against rust. In climates with a high degree of humidity it is advisable to use such pliers as they will last longer and need less maintenance. To keep pliers in good working condition, they should be kept clean, the metal parts should be wiped with an oily piece of cloth and, from time to time, a drop of oil should be applied to the pivots and joints. Diagonal cutter pliers Fig 27 shows diagonal cutting pliers or side cutting pliers. They are used for cutting small diameter wires and cables, especially when they are close to terminals.. End cutting pliers Fig 31 shows END-CUTTING PLIERS or END NIPPERS and their applications. They are used to cut small diameter wires, pins, nails and to remove nails from wood. End cutting pliers are made in the following overall lengths: 130, 160, 180, 200, 210 and 240 mm. Flat nose pliers Fig 32 shows a FLAT NOSE PLIERS and its applications. They are used to form and shape wires and small pieces of metal.
  28. 28 | P a g e Industrial Electrician They are also used for other operations such as removing the metal sheath from cables, or gripping and holding small parts. Flat nose pliers are made in the following overall lengths: 100, 120, 140, 160, 180 and 200 mm. Round nose pliers Fig 33 shows ROUND NOSE PLIERS and its applications. They are used to form curves in wires and light metal strips. The conical shape of the jaws makes it possible to form curves and circles of various dimensions. They are also used to form eyelets in wires to fit terminal screws, and to hold small parts. Round nose pliers are made to the following overall lengths: 100, 120, 140, 160, 180 and 200 mm Long nose pliers Fig 34 shows a LONG NOSE PLIERS and its applications. These pliers are made with straight and curved jaws. They are used to hold small parts, especially in confined areas. They are also used to adjust fine wires, contacts and other parts. Long nose pliers are made with many differently
  29. 29 | P a g e Industrial Electrician shaped jaws as shown in Fig 11. Long nose pliers are available in the following overall lengths: 160, 180, 200 and 220 mm. Combination pliers Fig 36 shows a COMBINATION PLIERS and its application. A number of operations can be performed with these pliers. The FLAT GRIP can be used to grip and hold parts and components and to twist wires. Circlip pliers for external Circlip Fig 37 shows a CIRCLIP PLIER for EXTERNAL CIRCLIPS. The prongs of the jaws are inserted into the holes of the Circlip. By applying pressure to the handles of the pliers, the jaws will expand the Circlip which can then be removed or moved onto the work piece. These pliers are available with straight and curved jaws in the following dimensions. Circlip pliers for internal Circlip Fig 38 shows ClRCLIP PLIERS for INTERNAL CIRCLIPS. By applying pressure to the handles of the pliers, the jaws will compress the Circlip which can then be removed from the work piece. These pliers are also available with straight and curved jaws in the following dimensions.
  30. 30 | P a g e Industrial Electrician Pliers used by electrician A number of pliers, especially diagonal cutting pliers, combination pliers, flat nose pliers, round nose pliers and long nose pliers, are frequently used by electricians. As an additional safeguard against electric shock, these pliers are available with insulated handles made of high quality rubber or plastic as shown in Fig 39. Before you work with electrical installations or electrical appliances, they have to be disconnected from the electrical supply. Working with live parts of an electrical installation or appliance can INJURE or KILL you, and it might seriously damage the Installation and equipment. Tweezers Tweezers are used to hold light weight and very small components and very thin wires/strands. Tweezers are classified according to the shape of the tip and are specified by their length and shape. Fig 40 shows different types of tweezers. The thin structure of the tweezers permits easy access to places where fingers cannot reach. Tweezers are very useful during soldering of wires, components and placing of small screws in interior places.
  31. 31 | P a g e Industrial Electrician Types of screws and screw heads Different types of screws used in various electrical applications and sizes are given below
  32. 32 | P a g e Industrial Electrician 2.3 ELECTRICAL ACCESSORIES USED IN INDUSTRIAL WIRING Switch board An electric switchboard is a device that directs electricity from one source to another. It is an assembly of panels, each of which contains switches that allow electricity to be redirected. Switch Board Distribution Board Distribution board A distribution board (or panel board) is a component of an electricity supply system which divides an electrical power feed into subsidiary circuits, while providing a protective fuse or circuit breaker for each circuit, in a common enclosure. Normally, a main switch, and in recent boards, one or more Residual-current devices (RCD) or Residual Current Breakers with Over current protection (RCBO), will also be incorporated Circuit breaker A circuit breaker is an automatically operated electrical switch designed to protect an electrical circuit from damage caused by overload or short circuit. Its basic function is to detect a fault condition and, by interrupting continuity, to immediately discontinue electrical flow. Unlike a fuse, which operates once and then must be replaced, a circuit breaker can be reset (either manually or automatically) to resume normal operation. Circuit breakers are made in varying sizes, from small devices that protect an individual household appliance up to large switchgear designed to protect high voltage circuits feeding an entire city. Electric meter An electricity meter or energy meter is a device that measures the amount of electric energy consumed by a residence, business, or an electrically powered device.
  33. 33 | P a g e Industrial Electrician Electricity meters are typically calibrated in billing units, the most common one being the kilowatt Measuring instruments Meter A meter is any device built to accurately detect and display an electrical quantity in a form readable by a human being. Usually this "readable form" is visual: motion of a pointer on a scale, a series of lights arranged to form a "bargraph," or some sort of display composed of numerical figures. In the analysis and testing of circuits, there are meters designed to accurately measure the basic quantities of voltage, current, and resistance. Different types of meter Ammeter A meter designed to measure electrical current is popularly called an "ammeter" because the unit of measurement is "amps." In ammeter designs, external resistors added to extend the usable range of the movement are connected in parallel with the movement rather than in series as is the case for voltmeters. This is because we want to divide the measured current, not the measured voltage, going to the movement, and because current divider circuits are always formed by parallel resistances. Voltmeter As was stated earlier, most meter movements are sensitive devices. Some D'Arsonval movements have full-scale deflection current ratings as little as 50 µA, with an (internal) wire resistance of less than 1000 Ω. This makes for a voltmeter with a full-scale rating of only 50 mill volts (50 µA X 1000 Ω)! In order to build voltmeters with practical (higher voltage) scales from such sensitive movements, we need to
  34. 34 | P a g e Industrial Electrician find some way to reduce the measured quantity of voltage down to a level the movement can handle. Wattmeter Power in an electric circuit is the product (multiplication) of voltage and current, so any meter designed to measure power must account for both of these variables. Three-Phase Wattmeter Total power in a 3f circuit is the sum of the powers of the separate phases. The total power could be measured by placing a wattmeter in each phase (Figure); however, this method is not feasible since it is often impossible to break into the phases of a delta load. It also may not be feasible for the Y load, since the neutral point to which the wattmeters must be connected is not always accessible. Normally, only two wattmeters are used in making 3f power measurements. Ohmmeter An ohmmeter is an electrical instrument that measures electrical resistance, the opposition to an electric current. Micro-ohmmeters (micrometer or micro ohmmeter) make low resistance measurements. Meg ohmmeters (aka mega ohmmeter or in the case of a trademarked device Megger) measure large values of resistance. The unit of measurement for resistance is ohms (Ω). Power factor meter The power factor of an AC electrical power system is defined as the ratio of the real power flowing to the load to the apparent power in the circuit, and is a dimensionless number between 0 and 1. Real power is the capacity of the circuit for performing work in a particular time. Apparent power is the product of the current and voltage of the circuit. .
  35. 35 | P a g e Industrial Electrician Linear loads with low power factor (such as induction motors) can be corrected with a passive network of capacitors or inductors. Non-linear loads, such as rectifiers, distort the current drawn from the system. In such cases, active or passive power factor correction may be used to counteract the distortion and raise the power factor. The devices for correction of the power factor may be at a central substation, spread out over a distribution system, or built into power-consuming equipment. High voltage ohmmeters (Megger)  It is a test of the insulation properties of such things as electric wiring, motor windings and high power antenna mounts. We use a "megger" or "meg out" electrical wiring and equipment to see if it is shorted to ground in any way. The megger uses much higher voltages to check resistance than a normal Volt-ohm meter. Resistance is measured between the Line and Earth terminals, where current will travel through coil 1. The "Guard" terminal is provided for special testing situations where one resistance must be isolated from another. Take for instance this scenario where the insulation resistance is to be tested in a two-wire cable: To measure insulation resistance from a conductor to the outside of the cable, we need to connect the "Line" lead of the megger to one of the conductors and connect the "Earth" lead of the megger to a wire wrapped around the sheath of the cable:
  36. 36 | P a g e Industrial Electrician In this configuration the megger should read the resistance between one conductor and the outside sheath. Or will it? If we draw a schematic diagram showing all insulation resistances as resistor symbols, Multimeter The multimeter is a portable single instrument capable of measuring various electrical values including voltage, resistance, and current. The volt-ohm-milliammeter (VOM) is the most commonly used multimeter. The typical VOM has a meter movement with a full scale current of 50 µA, or a sensitivity of 20 KW/V, when used as a DC voltmeter. A single meter movement is used to measure current, AC and DC voltage, and resistance. Range switches are usually provided for scale selection (e.g., 0-1V, 0-10V, etc).Seeing as how a common meter movement can be made to function as a voltmeter, ammeter, or ohmmeter simply by connecting it to different external resistor networks, it should make sense that a multi- purpose meter ("multimeter") could be designed in one unit with the appropriate switches) and resistors. This particular brand and model of digital meter has a rotary selector switch and four jacks into which test leads can be plugged. Two leads -- one red and one black -- are shown plugged into the meter. A close examination of this meter will reveal one "common" jack for the black test lead and three others for the red test lead. The jack into which the red lead is shown inserted is labeled for voltage and resistance measurement, while the other two jacks are labeled for current (A, mA, and µA) measurement. This is a wise design feature of the multimeter, requiring the user to move a test lead plug from one jack to another in order to switch from the voltage measurement to the current measurement function. It would be hazardous to have the meter set in current measurement mode while connected across a significant source of voltage because of the low input resistance, and making it necessary to move a test lead plug rather than just flipped the selector switch to a different position helps ensure that the meter doesn't get set to measure current unintentionally.
  37. 37 | P a g e Industrial Electrician volt/ammeter: If an ohmmeter function is desired in this multimeter design, it may be substituted for one of the three voltage ranges as such: With all three fundamental functions available, this multimeter may also be known as a volt-ohm-milliammeter. Neon Tester A handy inexpensive item to add to a tool box is the one dollar neon tester. It is useful to identify polarity in DC and identify the ungrounded conductor in AC circuits. For DC there is a polarity indicator. In AC simply hold one end of the tester between your fingers and touch the other end of the tester to the conductor to be measured. A slight glow will be present if you are on the ungrounded conductor. The only caution for that method was that both lamps had to be identical or at high voltage the higher resistance could explode. Not good. Sometimes the tester is made to be part of a screw driver. Sometimes it is made like a stick man with no arms. Another type of neon tester is the receptacle outlet tester, a very useful tool for every electrician. This item, when plugged into an outlet, will give you detailed indication of how the receptacle is wired. Be sure to hold on to the instructions. The diagrams of conditions on the unit will wear off over time. Perhaps that is the time to get a new one. Anyway, it is also useful before plugging in an electric tool. If the wiring to the receptacle is incorrect, that might be something to fix before using the outlet. Ground Detector The ground detector is an instrument which is used to detect conductor insulation resistance to ground. An ohm meter, or a series of lights, can be used to detect the insulation strength of an ungrounded distribution system. Most power distribution systems in use today are of the grounded variety; however, some ungrounded systems still exist. In the ground detector lamp method a set of three lamps connected through transformers to the system is used. To check for grounds, the switch is closed and the brilliance of the lamps is observed. If the lamps are equally bright, no ground exists and all the lamps receive the same voltage. If anyone lamp is dark, and the other two lamps are brighter, the phase in which the darkened lamp is in is grounded. In this case, the primary winding of the transformer is shorted to ground and receives no voltage. This may seem like an antiquated method but it works.
  38. 38 | P a g e Industrial Electrician Moving-Disk Frequency Meter Moving-disk frequency meters are most commonly out-of-circuit meters. They can be used to spot check the frequency of power sources or equipment signals. A moving-disk frequency meter having one coil tends to turn the disk clockwise, and the other, counterclockwise. Magnetizing coil A is connected in series with a large value of resistance. Coil B is connected in series with a large inductance and the two circuits are supplied in parallel by the source. For a given voltage, the current through coil A is practically constant. However, the current through coil B varies with the frequency. At a higher frequency the inductive reactance is greater and the current through coil B is less; the reverse is true at a lower frequency. The disk turns in the direction determined by the stronger coil. A perfectly circular disk would tend to turn continuously. This is not desirable, and so the disk is constructed so that it will turn only a certain amount clockwise or counterclockwise about the center position, which is commonly marked 60 hertz on commercial equipment. To prevent the disk from turning more than the desired amount, the left half of the disk is mounted so that when motion occurs, the same amount of disk area will always be between the poles of coil A. Therefore, the force produced by coil A to rotate the disk is constant for a constant applied voltage. The right half of the disk is offset, as shown in the figure. When the disk rotates clockwise, an increasing area will come between the poles of coil B; when it rotates counterclockwise, a decreasing area will come between the poles of coil B. The greater the area between the poles, the greater will be the disk current and the force tending to turn the disk. If the frequency applied to the frequency meter should decrease, the reactance offered by L would decrease and the field produced by coil B would increase. The field produced by coil A would remain the same. Thus, the force produced by coil B would tend to move the disk and the pointer counterclockwise. Selection of wire size Several factors must be considered in selecting the size wire to be used for transmitting and distributing electric power. There are military specifications that cover the installation of wiring of ships and electrical/electronic equipment. These specifications describe the technical requirements for material which is to be purchased from manufacturers by the Department of Defense. One important reason for these specifications is to reduce the danger of fires caused by the improper selection of wire sizes. Wires can carry only a limited amount of current safely. If the current flowing through a wire exceeds the current-carrying capacity of the wire, excess heat is generated. This heat may be great enough to burn off the insulation around the wire and continue to do much greater damage by starting a fire.
  39. 39 | P a g e Industrial Electrician Factors Affecting the Current Rating The current rating of a cable or wire indicates the current capacity that the wire or cable can safely carry continuously. If this limit, or current rating, is exceeded for a length of time, the heat generated may bum the insulation. The current rating of a wire is used to determine what size is needed for a given electrical load. The following factors determine the current rating of a wire:  The conductor size.  The material of which the conductor is made.  The location of the wire.  The type of insulation used.  Ambient temperature. Materials Marine cable insulation should be one of the following materials:  Polyvinyl chloride (designated T). This is the most common type of insulation currently used on modern vessels. It is a form of polymerized vinyl compound, resin, or plastic. The maximum conductor temperature that the insulation can handle is 75C. The voltage range is a maximum of 600 volts. The maximum allowable ambient temperature is 50C. It is of thermoplastic construction. This means it becomes soft when heated and rigid when cooled and cured. Polyvinyl chloride-protected cable provides a nonmetallic rigid sheathed cable. It is commonly called PVC. Moisture-Resistant Jackets An additional cable identification designation of I will be displayed on all cables with a moisture-resistant jacket. The jacket will be composed of one of the following:  Thermoplastic type T.  Thermoplastic type T covered with a nylon coating, which changes the designator to type N.  Thermosetting chlorosulfonated polyethylene (type CP). Separators and Fillers Separators may be provided inside the insulation to allow free stripping of cable conductors. Fillers eliminate air spaces in the cable. Marine cables will not permit the passage of water along the inside of a cable, nor will they support conductor oxidation. Additional insulating coding and specifications may be found in the Recommended Practice for Electrical Installations on Shipboard, the Institute of Electrical and Electronics Engineers, Inc. (IEEE Standard 45).
  40. 40 | P a g e Industrial Electrician Conductor Protection Wires and cables are generally subject to abuse. The type and amount of abuse depends on how and where they are installed and the manner in which they are used. Generally, except for overhead transmission lines, wires or cables are protected by some form of covering. The covering may be some type of insulator like rubber or plastic. Over this, an outer covering of fibrous braid may be applied. If conditions require, a metallic outer covering may be used. The type of outer covering used depends on how and where the wire or cable is to be used. Metallic armor provides a tough protective covering for wires or cables. The type, thickness, and kind of metal used to make armor depend on three factors:  The use of the conductors.  The circumstances under which the conductors are to be used.  The amount of rough treatment that is expected. Figure shows an armored cable. Basket-weave wire-braid armor is used wherever a light and flexible protection is needed. In the past, this type of armor covering has been used almost exclusively onboard ships. Wire braid is still used for special purposes in the engineering spaces. The individual wires that are woven together to form the braid are made out of aluminum or bronze. Besides mechanical protection, the wire braid also provides a static shield. This is important in radio work aboard ship to prevent interference from stray magnetic fields. Wiring Techniques Wire connections should be made inside the electrical component or inside watertight feeder, branch, or connection boxes. These boxes are generally brass or bronze. Watertight integrity is maintained by using stuffing tubes and gaskets. All the wire ends should be provided with lugs for connecting to bus terminals or for bolting and insulating individual wires together. During the course of normal electrical servicing, splicing wires is not authorized. Electrical cables must be continuous between the terminals except as outlined below:  Component subassemblies may be spliced together. Splices may not be made to the subassembly power supply cables or branch circuits.  Cables may be spliced to extend a circuit when a vessel is receiving authorized alterations.  An extremely long cable may be spliced to allow its proper and efficient installation as explained above.  Splicing is authorized for repair of damaged cables if the remainder of the cable is in good mechanical and electrical condition. The cable must be replaced in its entirety at the most opportune time.
  41. 41 | P a g e Industrial Electrician When electrical casualty requires expedient repairs, it is absolutely necessary that the repairs be made properly. A poor repair can prevent the operation of emergency equipment or develop into a tire. Any electric circuit is only as good as its weakest link. The basic requirement of any splice or connection is that it is both mechanically and electrically sound. The most common methods of making splices and connections in electrical cables are explained below. Splicing Splices should be located in an area that is easily accessible and inspect able. The splice should consist of the following components:  A conductor connector (terminal lugs, splice bolts, or splices)  A replacement jacket for the insulation.  A shunt or suitable conductor to maintain the electrical continuity between two severed pieces of the armor braid. Warning Continuity must be maintained between the armor covering and the vessel's hull at all times.
  42. 42 | P a g e Industrial Electrician ASSIGNMENTS 1. What is electron? 2. Define P.D. 3. Write Symbol for voltage, current and resistance? 4. What is AC? 5. Write difference between AC and DC. 6. Write five types of conductors. 7. Define Watt? 8. What is Rectifier? 9. What is Zero Potential? 10. Draw the Symbol of capacitor, Diode and Inductor. 11. What is the meaning of LED? 12. Write the name of 3 types of Screw driver. 13. Write the purposes/uses of pliers. 14. Write different types of Circlip pliers. 15. What is working nature of an electric switch board? 16. Calculate the current for the given circuit. In 240 volt AC a water heater of 2000 watt runs. What is rating of the circuit breaker? 17. Write the name of the instruments which are used for measuring power, voltage, current, frequency and power factor? 18. Write the units of followings. Power, Voltage, Current, Frequency, Resistance, Conductance. 19 How the tools are identified? 20. What is the process to find a cable to connect a load?
  43. 43 | P a g e Industrial Electrician 3.0 Electrical Circuits OBJECTIVES: understand and to study the electrical circuit. 3.1 TYPES OF WIRES AND CONDUCTORS, LOAD CARRYING CAPACITY A wire is a single, usually cylindrical, flexible strand or rod of metal. Wires are used to bear mechanical loads and to carry electricity and telecommunications signals. Wire is commonly formed by drawing the metal through a hole in a die or draw plate. Standard sizes are determined by various wire gauges. The term wire is also used more loosely to refer to a bundle of such strands, as in 'multistranded wire', which is more correctly termed a wire rope in mechanics, or a cable in electricity. Although usually circular in cross-section, wire can be made in square or flattened rectangular cross-section, either for decorative purposes, or for technical purposes such as high-efficiency voice coils in loudspeakers. Edge-wound coil springs, such as the "Slinky" toy, are made of special flattened wire. Finishing, jacketing, and insulating Electrical wires are usually covered with insulating materials, such as plastic, rubber-like polymers, or varnish. Insulating and jacketing of wires and cables is nowadays done by passing them through an extruder. Formerly, materials used for insulation included treated cloth or paper and various oil-based products. Since the mid-1960s, plastic and polymers exhibiting properties similar to rubber have predominated. Two or more wires may be wrapped concentrically, separated by insulation, to form coaxial cable. The wire or cable may be further protected with substances like paraffin, some kind of preservative compound, bitumen, lead, aluminum sheathing, or steel taping. Stranding or covering machines wind material onto wire which passes through quickly. Some of the smallest machines for cotton covering have a large drum, which grips the wire and moves it through toothed gears; the wire passes through the centre of disks mounted above a long bed, and the disks carry each a number of bobbins varying from six to twelve or more in different machines. A supply of covering material is wound on each bobbin, and the end is led on to the wire, which occupies a central position relatively to the bobbins; the latter being revolved at a suitable speed bodily with their disks, the cotton is consequently served on to the wire, winding in spiral fashion so as to overlap. If a large number of strands are required the disks are
  44. 44 | P a g e Industrial Electrician duplicated, so that as many as sixty spools may be carried, the second set of strands being laid over the first. Solid versus stranded Stranded copper wire Solid wire, also called solid-core or single-strand wire consists of one piece of metal wire. Stranded wire is composed of a bundle wires to make a larger conductor. Stranded wire is more flexible than solid wire of the same total cross-sectional area. Solid wire is cheaper to manufacture than stranded wire and is used where there is little need for flexibility in the wire. Solid wire also provides mechanical ruggedness; and, because it has relatively less surface area which is exposed to attack by corrosives, protection against the environment. Stranded wire is used when higher resistance to metal fatigue is required. Such situations include connections between circuit boards in multi-printed-circuit-board devices, where the rigidity of solid wire would produce too much stress as a result of movement during assembly or servicing; A.C. line cords for appliances; musical instrument cables; computer mouse cables; welding electrode cables; control cables connecting moving machine parts; mining machine cables; trailing machine cables; and numerous others. At high frequencies, current travels near the surface of the wire because of the skin effect, resulting in increased power loss in the wire. Stranded wire might seem to reduce this effect, since the total surface area of the strands is greater than the surface area of the equivalent solid wire, but ordinary stranded wire does not reduce the skin effect because all the strands are short-circuited together and behave as a single conductor. A stranded wire will have higher resistance than a solid wire of the same diameter because the cross-section of the stranded wire is not all copper; there are unavoidable gaps between the strands (this is the circle packing problem for circles within a circle). A stranded wire with the same cross-section of conductor as a solid wire is said to have the same equivalent gauge and is always a larger diameter. Galvanized: You can find this (along with copper wire) in most hardware stores. It is a dull silver color and is also good practice wire. This wire is harder than the silver wire you may be used to, so get a small gauge if you plan to get some. Sterling Silver: This is one of my favorite types of wire because sterling wire works the best for many of my finished jewelry pieces. Sterling indicates that the wire is 92.5% pure silver. The rest is made up of alloys (such as copper or zinc) to provide strength. Sterling will tarnish, called oxidation, so it's best to keep in zip lock bags or sealed containers of some kind when not using it for jewelry or wearing the jewelry itself. When it does tarnish (and it eventually will), you can polish by using a polishing kit, using a magnetic polisher or tumbler, or you can clean it with an ionic cleaner.
  45. 45 | P a g e Industrial Electrician Fine Silver: Made of 99.9% pure silver, many wire workers enjoy working with fine silver. Fine silver is softer than sterling. Since it has fewer alloys, it also does not tarnish as quickly as sterling silver does. Gold-filled: First of all, never call gold-filled wire, "gold wire." It is used many times by jewelry makers, while gold-filed metal has many layers of gold, it is not pure gold. On the upside, gold-filled is of much better quality than plated gold (only one layer) so gold-filled lasts for a very long time if cared for properly. It is a wonderful alternative to gold, which is pretty darn expensive! Gold: If you are daring enough and feel comfortable enough, go for the gold! Many jewelry vendors offer real gold wire in various karats (10-24 for example) and even different colors. Coated Colors: Often coated wire is coated with an enamel to create the color of the wire. This wire has become very popular and is even available in many large craft stores. It is a lot of fun to work with. However, due to the coating, it can be marked by metal tools, so keep this in mind when using it. 1. Triplex Wire Triplex is an aerial cable that the utility company uses to feed the power pole. This wire ties to the wires sticking out of the weather head. 2. Main Feeder Wires These wires are usually type THHN wire and are rated for 125% of the load required. These are usually black insulated wires coming out of the service weather head. 3. Panel Feed Wires These wires are also type THHN, like the main feeders. A typical 100-amp service would have a #2 THHN set of wires. They would then be rated at 125 amps. This would protect the wires if the amperage was a full 100 amps. 4. Non-Metallic Sheathed Wire (NM) This wire, commonly called Romex, is a plastic coated wire that has either two or three conductors and a bare ground wire. This is the typical wiring used in most homes. The rating for this wire is either 15 amps, 20 amps, or 30 amps, depending on the installation.
  46. 46 | P a g e Industrial Electrician 5. Single Strand Wire When your home is piped, you’ll have to have another type of wire. Single strand wire is insulated and many of these can be pulled into the same pipe. Normally, you’ll be using THHN wire for this installation. Types of Conductors in Transmission Lines A conductor is a material that facilitates the flow of electricity (or electric current) through a transmission line. Different types of conductors are used in transmission lines. They vary in number and size, depending on the type of circuit and the transmission voltage. Steel, aluminum and copper are the most common conducting materials used in transmission lines. Copper: Copper is abundantly available in nature, is an excellent conductor of electricity and can be readily spliced. Copper conductors exist in one of three forms: soft drawn (or annealed), medium drawn and hard drawn. Soft-drawn copper conductors are commonly used in short transmission line spans and to ground electrical systems. They are flexible and resistant to breaking even under high stress. Medium-drawn copper conductors are used for medium- range distribution lines, while hard-drawn copper conductors are used in longer spans (greater than 200 feet) and are the strongest of the three. Their strength, however, makes them inflexible and often difficult to work with. Steel According to "The Electronics Handbook," steel conductors are one tenth as effective as copper conductors and rust easily--due to which steel conductors are hardly used alone. Steel conductors are commonly galvanized (or coated with a layer of zinc to counteract their rusting tendency). According to "Guide to Electrical Power Distribution Systems," steel- based transmission conductors are three to five times stronger than copper conductors, and can be used for longer spans with fewer supports. Aluminum According to "Electrical Craft Principles," Volume 1, aluminum can rapidly oxidize, has higher thermal expansion, lower strength, and less than half the conductivity of copper. It is, however, lighter and half as resistant as copper. There are two types of aluminum commonly used as transmission line conductors: heat-treatable alloy and pure metal grade. Aluminum conductors are commonly used for higher-voltage overhead transmission lines, power cables, busbars, motors, heating elements, heat sinks and foil windings.
  47. 47 | P a g e Industrial Electrician Steel-Reinforced Aluminum Steel-reinforced-aluminum conductors are commonly used in medium-, high- and extra- high-voltage (EHV) transmission lines. They are also called ACSR or aluminum-conductor steel-reinforced conductors. ACSR transmission lines are high-strength, high-capacity and exhibit excellent conductivity. They are lightweight and used in overhead transmission lines, river crossings and longer spans. ACSR transmission lines have a central steel strand, surrounded by outer aluminum strands. The steel conductor supports the weight of the transmission line while the aluminum is used for its conductive properties. ACSR transmission cables are available in specific sizes and varying amounts of central steel strands as well as outer aluminum conductors. 3.2 WIRING DIAGRAMS. A wiring diagram is a simplified conventional pictorial representation of an electrical circuit. It shows the components of the circuit as simplified shapes, and the power and signal connections between the devices. A wiring diagram usually gives more information about the relative position and arrangement of devices and terminals on the devices, to help in building the device. This is unlike a schematic diagram where the arrangement of the components interconnections on the diagram does not correspond to their physical locations in the finished device. A pictorial diagram would show more detail of the physical appearance, whereas a wiring diagram uses a more symbolic notation to emphasize interconnections over physical appearance. A wiring diagram for parts of an electric guitar, showing semi-pictorial representation of devices arranged in roughly the same locations they would have in the guitar. A wiring diagram is used to troubleshoot problems and to make sure that all the connections have been made and that everything is present. An automotive wiring diagram, showing useful information such as crimp connection locations and wire colors. These details may not be so easily found on a more schematic drawing.
  48. 48 | P a g e Industrial Electrician House/ Residential Wiring Diagram of a Typical Circuit Lighting Circuit Diagrams These diagrams show various methods of one, two and multiple way switching. L and N indicate the supply. Switches are shown as dotted rectangles. Earth wires are not shown. One way switching two way switching, 2 wires This arrangement would typically be used in conduit, and uses two wires between each switch. It can also be used in domestic properties by using twin earth cable between the switches,
  49. 49 | P a g e Industrial Electrician and 1core+earth from the switches to the ceiling rose. Unfortunately, this is usually uncounted in stairwells, with the line from the downstairs lighting circuit and the neutral connected to the upstairs lighting circuit. Such an arrangement is not permitted, as isolating only one of the circuits leaves live wiring depending on the position of the light switches. Two way switching, 3 wires More common in domestic properties. Twin earth from the ceiling rose to the first switch, and three wires between the switches, usually 3 core and earth cable. This is also known as the 'conversion' method, since it is the easiest way to add a second light switch to an existing circuit. Three way switching, 3 wires Three way switching, 2 wires Three wires between the two end switches, probably using 3 core and earth cable. Usually the third wire passes the middle intermediate switch but is joined in a separate terminal block. Two wires between each switch. Most likely to be found with wires in conduit. The middle switch is an intermediate type.
  50. 50 | P a g e Industrial Electrician Industrial Wiring When wearegoing for industrial wiring it’s different ,weare using two types of circuits control & power circuit. In control circuit we control all the switching device & and the coil parts,but in case of power circuit we control motor with three phase supply. 3-Phase motor control circuit
  51. 51 | P a g e Industrial Electrician Over Head Line An overhead line, or overhead wire, is used to transmit electrical energy to trams, trolleybuses or trains at a distance from the energy supply point. It is known variously as  Overhead contact system (OCS)  Overhead line equipment (OLE or OHLE)  Overhead equipment (OHE)
  52. 52 | P a g e Industrial Electrician  Overhead wiring (OHW) or overhead lines (OHL)  Catenary In this article the generic term overhead line is used. This is also the term used by the International Union of Railways. Overhead line is designed on the principle of one or more overhead wires or rails (particularly in tunnels) situated over rail tracks, raised to a high electrical potential by connection to feeder stations at regular intervals. The feeder stations are usually fed from a high-voltage electrical grid. Overview Electric trains that collect their current from an overhead line system use a device such as a pantograph, bow collector, or trolley pole. The device presses against the underside of the lowest wire of an overhead line system, the contact wire. The current collectors are electrically conductive and allow current to flow through to the train or tram and back to the feeder station through the steel wheels on one or both running rails. Non-electric trains (such as diesels) may pass along these tracks without affecting the overhead line, although there may be difficulties with overhead clearance. Alternative electrical power transmission schemes for trains include third rail, ground-level power supply, batteries, and electromagnetic induction. This article does not cover regenerative braking, where the traction motors act as generators to retard movement and return power to the overhead. Typical constructions of overhead lines Along streets, alleys, through woods, and in backyards, many of the distribution lines that feed customers are overhead structures. Because overhead lines are exposed to trees and animals, to wind and lightning, and to cars and kites, they are a critical component in the reliability of distribution circuits. Overhead constructions come in a variety of configurations. Normally one primary circuit is used per pole, but utilities sometimes run more than one circuit per structure. For a three-phase circuit, the most common structure is a horizontal layout with an 8- or 10-ft wood crossarm on a pole. Armless constructions are also widely found where fiberglass insulator standoffs or post insulators are used in a tighter configuration. Utilities normally use 30- to 45-ft poles, set 6 to 8 ft deep. Vertical construction is also occasionally used. Span lengths vary from 100 to 150 ft in suburban areas to as much as 300 or 400 ft in rural areas.
  53. 53 | P a g e Industrial Electrician Distribution circuits normally have an under built neutral — the neutral acts as a safety ground for equipment and provides a return path for unbalanced loads and for line-to- ground faults. The neutral is 3 to 5 ft below the phase conductors. Utilities in very high lightning areas may run the neutral wire above the phase conductors to act as a shield wire.
  54. 54 | P a g e Industrial Electrician Example cross arm construction Some utilities also run the neutral on the crossarm. Secondary circuits are often run under the primary. The primary and the secondary may share the neutral, or they may each have their own neutral. Many electric utilities share their space with other utilities; telephone or cable television cables may run under the electric secondary. Wood is the main pole material, although steel, concrete, and fiberglass are also used. Treated wood lasts a long time, is easy to climb and attach equipment to, and also augments the insulation between the energized conductors and ground. Conductors are primarily aluminum. Insulators are pin type, post type, or suspension, either porcelain or polymer. The National Electrical Safety Code (IEEE C2-2000) governs many of the safety issues that play important roles in overhead design issues. Poles must have space for crews to climb them and work safely in the air. All equipment must have sufficient strength to stand up to “normal” operations. Conductors must carry their weight, the weight of any accumulated ice, plus withstand the wind pressure exerted on the wire.
  55. 55 | P a g e Industrial Electrician 3.3 CONDUCTORS AND INSULATORS Conducting Material It is the part of the accessory through which the current passes. It is usually made of copper or brass. Its current rating depends on the maximum current that can flow through it without pro- ducing any harm. For example, if a switch is designed for 15 A, it means that we can easily pass 15 A through its conducting material, but on passing higher current then specified, say 15 A, it will be overheated and may burn due to sparking, etc. Thus, the use of a particular accessory is limited only for the current rating specified. A neutrally charged conductor and its response to charged objects being brought near it. In a conductor (usually metal) many of the electrons are free to to move around within the conductor. Conductors are often referred to as having a "sea of electrons" since the movement of the electrons looks like a flowing sea. As the positively charged rod is brought near the conductor, the electrons are attracted toward the charged rod. This causes a force of attraction to be created between the rod and the conductor. As the negatively charged rod is brought near the conductor, the electrons are repelled away from the charged rod. This causes a force of attraction to be created between the rod and the conductor. As a result, we can say that a charged object will always be attracted by a conductor. Notice that only the electrons are free to move, the protons are fixed in place because they make up the mass of the conductor. It is also important to notice that when no charged object is near the conductor, the electrons evenly distribute themselves within the conductor.
  56. 56 | P a g e Industrial Electrician Insulating Material It is the substance which binds the current to flow in a definite direction, or in other words, the substance which does not allow the leakage current to flow through. Their rating is considered according to the maximum safe working voltage at which no leakage of current can take place through the insulation. If the rating of the switch is 250 V, it means the insulation can withstand 250 V and there will be no leakage current, but at a higher value of voltage, the current could leak through the insulation. The insulating material that is used for electrical accessories is either Bakelite or porcelain. The animation at the left is showing a neutrally charged insulator and its response to a charged object being brought near it. In an insulator (such as plastic, rubber, glass, etc) the electrons are not free to move around the entire object. They are generally restricted to moving only around the atom they are attached to. They can move from one side of the atom to the other but are unable to leave the atom. As a result, we say that charges stay where you put them on an insulator. Notice in the animation that the electrons are evenly distributed but are still attached to only one of the positive charges. As the negatively charged rod is brought near the insulator, notice that the electrons move to the other side of the positive charges but are unable to move completely to the far side of the object. Even though the charges only move to the other side of the atom you should notice that the upper side of the insulator becomes more positive and therefore feels a force of attraction to the the charged object. There would also be an attraction if the object was positively charged. as a result we say that a neutral insulator will always be attracted to a charged object. Insulator A substance which (at a particular voltage) does not allow the flaw of electrons (current) through them is called an insulator. For example, some of the good insulators are mica, porcelain, glass, rubber, Bakelite, etc. In insulators the electrons are closely and strongly bound to the nucleus. There are very few free electrons in them and the interchange between atoms is little. Therefore, insulators do not conduct any electric current or conduct very little if a very high potential difference is applied across them. Qualities of Insulating Materials The following are the main qualities of good insulating materials which should be consider- ed while selecting a particular one for use:  It should be flexible.  It should have good mechanical strength.  It should be non absorptive of moisture.
  57. 57 | P a g e Industrial Electrician  It should be easily molded to any shape.  It should be noninflammable.  It should not be affected by acids or alkalies. It should have high specific resistance to reduce the possibilities of leakage current. It should be capable of working at high temperature because insulators lose their insulating proper- ties as the temperature increases. It should have high dielectric strength, i.e. the value of the voltage at which the breakdown takes place in a plate of insulator 1 mm thick should be high. Dielectric strength of an insu- lator is measured in kilovolts per millimeter thickness. The majority of insulating materials available for use in the construction of electrical machi- nes and apparatus have only a few of the above mentioned properties. It is, therefore, the work of the designer to select a particular insulation for the purpose for which it is required. Application of conductor and insulator In the application of electrical wiring: the conductor (e.g. copper) carries the electricity where it is needed the insulator (e.g. PVC) around the conductor keeps the electricity from going where it... 3.4 CONCEPTS OF AC, DC, SINGLE PHASE AND 3 PHASE SUPPLY Alternating Current (AC) Alternating Current (AC) flows one way, then the other way, continually reversing direction. An AC voltage is continually changing between positive (+) and negative (-). The rate of changing direction is called the frequency of the AC and it is measured in hertz (Hz) which is the number of forwards-backwards cycles per second. Mains electricity in the India has a frequency of 50Hz. See below for more details of signal properties. An AC supply is suitable for powering some devices such as lamps and heaters but almost all electronic circuits require a steady DC supply (see below).
  58. 58 | P a g e Industrial Electrician Direct Current (DC) Steady DC from a battery or regulated power supply, this is ideal for electronic circuits. Smooth DC from a smoothed power supply, this is suitable for some electronics component. Direct Current (DC) always flows in the same direction, but it may increase and decrease. A DC voltage is always positive (or always negative), but it may increase and decrease. Electronic circuits normally require a steady DC supply which is constant at one value or a smooth DC supply which has a small variation called ripple. Cells, batteries and regulated power supplies provide steady DC which is ideal for electronic circuits. Power supplies contain a transformer which converts the mains AC supply to a safe low voltage AC. Then the AC is converted to DC by a bridge rectifier but the output is varying DC which is unsuitable for electronic circuits. Varying DC Properties of electrical signals from a power supply without smoothing, this is not suitable for electronics. An electrical signal is a voltage or current which conveys information, usually it means a voltage. The term can be used for any voltage or current in a circuit. The voltage-time graph on the right shows various properties of an electrical signal. In addition to the properties labeled on the graph, there is frequency which is the number of cycles per second. The diagram shows a sine wave but these properties apply to any signal with a constant shape.
  59. 59 | P a g e Industrial Electrician Amplitude Amplitude is the maximum voltage reached by the signal. It is measured in volts, V. Peak voltage is another name for amplitude. Peak-peak voltage Peak-peak voltage is twice the peak voltage (amplitude). When reading an oscilloscope trace it is usual to measure peak-peak voltage. Time period Time period is the time taken for the signal to complete one cycle. It is measured in seconds (s), but time periods tend to be short so milliseconds (ms) and microseconds (µs) are often used. 1ms = 0.001s and 1µs = 0.000001s. Frequency Frequency is the number of cycles per second. It is measured in hertz (Hz), but frequencies tend to be high so kilohertz (kHz) and megahertz (MHz) are often used. 1kHz = 1000Hz and 1MHz = 1000000Hz. frequency = 1 and time period = 1 time period frequency Mains electricity in the India has a frequency of 50Hz, so it has a time period of 1 /50 = 0.02s = 20ms. Root Mean Square (RMS) Values The value of an AC voltage is continually changing from zero up to the positive peak, through zero to the negative peak and back to zero again. Clearly for most of the time it is less than the peak voltage, so this is not a good measure of its real effect. Instead we use the root mean square voltage (VRMS) which is 0.7 of the peak voltage (Vpeak): VRMS = 0.7 × Vpeak and Vpeak = 1.4 × VRMS These equations also apply to current. They are only true for sine waves (the most common type of AC) because the 0.7 and 1.4 are different values for other shapes. The RMS value is the effective value of a varying voltage or current. It is the equivalent steady DC (constant) value which gives the same effect. What do AC meters show, is it the RMS or peak voltage?
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