Workshop Manual

EE 101 ELECTRICAL WORKSHOP PRACTICE LAB MANUAL
ELECTRICAL WORKSHOP PRACTICE

LABORATORY
LIST OF EXPERIMENTS
EXPERIMENT EXPERIMENT TITLE Page

# No
1 Introduction & Usage of Tools: 2
Introduction and use of Electrical tools, Electrical materials.
2 T-Joint & Straight Joint: 6
To learn and make T-joint & Straight joint
3 Staircase Wiring: 9
To study and implement staircase wiring using two way switches.
4 House Wiring: 11
To study old and new house wiring schemes.
5 Fluorescent Tube Light: 15
To study and observe working of fluorescent tube light with and without
starter.
6 Sodium Vapour Lamp: 17
To find the light wavelength of sodium vapour lamp.
7 DC Machines: 20
To study commutation process, DC motor & generator working.
8 Slip Ring Machines: 23
To study and observe working of Slip ring machines with unconnected
and connected rotor windings
9 PCB Designing: 28
To learn PCB Designing and to design a sample circuit on a PCB
SHEET
10 Repairing of Home Appliances: 30
To study repairing of home appliances such as Heater, Electric iron
and fans etc.
11 Transformer Winding: 34
To study and make transformer winding.
12 Layout on Metal Sheet: 37
To prepare layout on a metal sheet by marking and prepare rectangular
tray
13 Drilling: 39
To mark punch and drill holes on a metal sheet.
14 Wielding: 41
To prepare Joints for butt- welding and lap welding.
Instructor: Aashir Waleed, Lecturer Electrical Engg. Dept, UET Fsd Page 1
Name
Reg. #
Marks
EXPERIMENT # 1
Introduction & Usage of Tools

Objectives:
Introduction and use of Electrical tools, Electrical materials.
Apparatus:
Basic electric and workshop tools
Theory:
1.1: Tools
PLIER:
Generally three types of pliers are used in the electrical workshop. They are:-
1. FLAT NOSE PLIER: Used for holding jobs or holding wires. It has got
only two slotted jaws, which are tapered. Thus it is used for tightening or
loosening small nuts.
2. SIDE CUTTING PLIER: Used for cutting of thin wires and removing
insulations from them. It has got cutting edge on its one of its sides.
3. ROUND NOSE PLIER: Used only to hold or cut the wires. It has no
gripping jaws. Its cutting edge is long and rounded on the top.
SCREW DRIVER:
It is used to loosen or tighten or to keep screws in position. It has a wooden
or plastic handle and a blade of high carbon steel.
CHISEL:
1. FIRMER CHISEL: Generally used for carpentry works and can be used
by hand pressure or with the help of mallet. It has flat blade, which varies
from 12mm to 15mm.
2. COLD CHISEL: Used for cutting iron pieces (cold). It has cutting angle
from 30° to 45°and is made of high carbon steel.
HAMMER:
Most commonly used in the workshop. The head is made of cast iron or forged;
the claw is hardened and tampered. The striking place is slightly convex. The
head is fitted with a wooden handle of various lengths.
HACKSAW:
Used to cut metal such as iron strips, core pipes etc. it has a blade made of high
steel or tungsten.
MALLET:
A mallet is a kind of hammer, usually of rubber, or sometimes wood smaller

than a maul or beetle and usually with a relatively large head.
CENTRE PUNCH:
A punch is a hard metal rod with a shaped tip at one end and a blunt butt end at
the other, which is usually struck by a hammer. Punches are used to drive
objects, such as nails, or to form an impression of the tip on a work piece.
Decorative punches may also be used to create a pattern or even form an image
1.2: Electrical Tools
TUMBLER SWITCH:
(6 A for light), this switch was used 3-4 decade ago. It is made of Bakelite.
MCB BOX:
Known as the Miniature Circuit Breaker Box.
METAL CONDUIT PIPE WITH JUNTION BOX:
Metallic hollow pipe, which is used as a passage for electrical house, hold
wires. It is fixed to walls with the help of metallic saddle.
METAL BEND:
Hollow metallic pipe bend to an angle of 90° to allow smooth movement of

wires inserted through the walls during wiring
PVC CASING AND LAPPING:
Long rectangular box made of 2 parts. It is made of PVC and used mainly to
pass wires through walls during wiring.
PVC BEND:
Work similarly as metal bends but it is made up of PVC that makes it lighter,
Cheaper and more durable.
BATTEN LAMP HOLDER:
Mainly used to hold electric bulbs and lamps.
SWITCH BOARD WITH SWITCHES:

It contains the following:
1. SOCKET OUTLETS: it is a type of electrical material through which

electric current flows from wires to various electrical appliances. It is of
6A.
2. TWO WAY SWITCH: it is mainly used in staircase wiring to either on or

off the light. It is of 6A.
3. ONE-WAY SWITCH: it is a device used to switch on lights of 6A.
7/29 SWG (POWER WIRE):
They are used in power purposes for duty electrical appliances. 7/29 means 7
numbers of wires in the cable and 29 strands for thickness or gauge size.
3/29 SWG (PHASE WIRING):
Mostly used for house wiring purposes.
3/29 SWG (NEUTRAL WIRE):
It is also used for house wiring purposes.
1/18 SWG:
It is used for earthing.
FLEXIBLE CABLE:
This is a temporary wire used for both power and light but temporarily. It is
used as extension wire.
Lab Exercise:
What is the function of hack saw?

Q.1
Q.2 How many types of pliers we used?
Q.3 What is the function of chisel?
Q.4 What is the function of screwdriver?
Q.5 Why we use flexible wires?
Conclusions: Write your observations & comments in the space provided

below:
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EXPERIMENT # 2
T-Joint & Straight Joint

Objectives:
To learn and make T-joint & straight joint
Apparatus:
1. Side-cutting plier
2. 1/18 SWG
3. 3/29 SWG wires
Theory:
2.1:T-Joint
It is used to take connections from a horizontal line and it is also

known as parallel point.
2.2:Straight Joint
it is used to increase the length of the 3 standard wires
Procedure:
T-joint:
1. Take 2 horizontal and vertical lengths of wires 30cm and 20cm

respectively to which the joint is to be made.
2. Remove the insulation of taping vertical length of 7.5cm
3. Remove the insulation of straight length middle portion
4. Remove the insulation of 12mm on each side of the base wire.
5. Hold the wire at 90° to running and make a neck turn to void slipping of
joint
6. Wrap off conduction closely and tightly 6-8 turns on horizontal wire.
7. Round off the conductor with the help of a plier.
8. The joint is soldered and insulated with tape Use PVC case wiring to
cover expose wiring.
Straight Joint:
1. Cut two pieces of cable of nearly the same length.
2. Remove the insulation from the end of both the cable pieces.
3. Separate the wire from both the cables and join the 2 cables in such a way
that the individual wires are joint separately
4. For half of the length of the di-insulated cable overlapped make a trust
with the help of a plier.
5. Complete the remaining half-length on the twist with the help of a plier
6.
Precautions:
1. Tools should be used carefully
2. Fitting should be tightly fitted
3. Connection should be tight.
4. Wire should be on the conduit, power gripped properly
Diagram:
Fig. 2.1 T-Joint
Fig.2.2 Straight Joint
Lab Exercise:
Why we make a T joint?

Q.1
What does you meant by 3/22 SWG?
Q.2
What is the application of straight joint?
Q.3
Q.4 What is the main precaution to make the

joints?
Which joint we use for tap connection
Q.5 from horizontal line?
Which tool is used for twisting the wires?
Q.6
Which joint is used for Fan connection?

Q.7
What is SWG of earthing wire?
Q.8
How we increase the length of conductor?
Q.9
What is the function of a cutter?
Q.1
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below:
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EXPERIMENT # 3
Staircase Wiring
Objectives:
To study and implement staircase wiring using two way switches
Apparatus:
1. 3/29 SWG wires
2. lamp holders
3. two way switch
4. 40w bulb
5. 3PVC casing
6. strips and pliers.
Theory:
It is that wiring which makes use of 2 switches to operate bulb at

the beginning of the stair lights and the bulb gives off by pushing the button in
the end. One of the terminals of the bulb is connected to the main line whose
power line is connected to middle slot of two-way switch. Remaining first of
there slots is connected in parallel as in crossed node.
Procedure:
1. Plan the wiring and casing according to the circuit diagram.
2. With the help of pliers and stripper share the ends of wire of required
length.
3. Connect the wire carrying the current to the central pin of the two-way
switch.
4. Connect the remaining ends A and B to the corresponding other two way
switch.
5. Connect the center pin wire of second two-way switch to the lamp.
6. Connect the second point to the neutral for completing the circuit.
7. Use PVC case wiring to cover expose wiring.
8. Switch ON and OFF the two switches alternatively to the bulb.
Precautions:
Diagram:
Fig. 3.1 Staircase Wiring
Lab Exercise:
Which type of switch we use in stair case

Q.1 wiring?
Q.2 Which tools are used for wiring?
Q.3 What is the main precaution for staircase

wiring?
Q.4 What is the link clips?
Q.5 What is the function of megger & saw?

below:
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EXPERIMENT # 4
House Wiring
Objectives:
To study old and new wiring schemes
Apparatus:
1. Tenon saw
2. screwdriver 8 cm (8”),
3. Screwdriver 15(6”)
4. Connector Screwed river,
5. Hammer,
6. Pliers
7. Drill machine,
8. Try square,
9. Chisel,
10.File,
11.Poker knife
Material & Quantity
T.W Batten 19mm x 13mm 42m
CTS/ T.R.S wire 13/. 039(3/22) 250v
Batten holder 2no.
Plug 3pin, 5amp 1no.
T.W round blocks (7.75cm x 2.5) 3 no.
Tumbler Switch one-way 5amp 3 no.
T.W batten 13mm x 13mm 10m
T.W board 40 mm(1+1/2”)
Wood Screw
Link clip 40 mm(1/2”)
Theory:
This type of wiring is used in houses. The two terminal of supply are connected
to meter and other two terminals are joined to DPIC. One end is attached to N-
link of fuse is joined to switch board of a room and neutral pole is also
connection to switch board according to our need.
4.1: Types of House Wiring
Following are house wiring types
4.1.1: Cleat Wiring
This is of wiring suitable only for temporary wiring purpose. In lamp or

wet location the wire used should be moisture proof and a weather proof.
4.1.2: PVC Conduit Wiring
This uses a conduit pipe for the mechanical protection of wire. In this
system of wiring, wires are carried through P.V.C conduit pipe for giving
converging to pipes conduit pipe has certain advantage like it is moisture
proof and durable
4.1.3: Batten Wiring
This type of wiring is mostly used for fixing cables on a wooden structure
called batten by means of metal. It is the surface wiring system whenever
wires are broken for connecting to switch on the right point junction box
made up of either part plastic or metal C.I must be used and provided
same means of earthing
4.1.4:PVC Casing Wiring
This type of wiring is mostly used for indoor and domestic wiring carried
through a P.V.C casing wiring
Procedure:
1. Draw the tangent or wiring on the board with chalk.
2. Cut the required length of T.W batten file and link chips on then and file
the batten with screw of 3mm size.
3. Cut the C.T.S wire in required length and put them on batten gripped by
link chips or per circuit diagram.
4. Fix the T.W round blocks and board after drilling the holes for wire.
5. Fix the batten holder, 3-pin plug and switch on round block.
6. After completing wiring it should be checked before supplying current
Precautions:
Diagram:
Fig. 4.1 House Wiring
Lab Exercise:
How much voltage in a single-phase

Q.1 supply?
Q.2 What do you meant by DPIC?

What is the bus bar?
Q.3
Q.4 How we represent the lamp?

Why we use regulator?
Q.5
What is the maximum Load on a
Q.6 switchboard?
What is MCB?
Q.7
What is cleat wiring?
Q.8
What is the color code of wiring?
Q.9
What do you meant by PVC?

Q.1
0

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EXPERIMENT # 5
Fluorescent Tube Light

Objectives:
To study and observe working of fluorescent tube light with and without starter.
Apparatus:
1. Tube
2. Tube Base
3. Starter
4. Choke
5. Wire
Theory:
Fluorescent tube is a low-pressure mercury vapor lamp. The lamp

is in the form of long glass tube due to low pressure, with fluorescent powder
coating to its inner surface. Tungsten filaments coated with barium oxide are
placed at each side of the tube. The tube contains small amount of mercury with
small quantity of argon gas at low pressure. When the temperature increases
mercury changes into vapor form. At each end of the tube, electrode in spiral
form is made of tungsten coated with electrons emitting barium. A capacitor is
connected across the circuit to improve the power factor..
Procedure:
1. Fix the tube holder and the choke on the tube base.
2. Phase wire is connected in the choke and neutral direct to the tube.
3. Fix the fluorescent tube between the holders.
4. Finally connect the starter in series with the tube.
Precautions:
1. Be careful and attentive while working on appliances.
2. Use proper tools for each operation
Diagram:
Fig. 5.1 Flourescent Tube Light
Lab Exercise:
What is the standard dia. of the tube light?

Q.1
Q.2 Which material is used for coating the

tube?
Q.3 What are the standard lengths of tube

light?
Q.4 Which gas is used in tube light?

What is the function of starter?
Q.5
Q.6 Why we use choke in tube light?

Name any two types of the starter?
Q.7
At which supply the tube is operated?
Q.8
Q.9 How much power consumed by the tube

light?
Q.1 Can we start the tube light with out a

0 starter?

below:
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EXPERIMENT # 6
Sodium Vapour Lamp

Objectives:
To find the light wavelength of sodium vapor lamp.
Apparatus:
1. Sodium lamp
2. Power supply
Theory:
Sodium vapor lamp consists of an inner tube (made of special

sodium vapor resistant glass) housing two tungsten electrode, which are
connected across an autotransformer. Inner U tube containing neon gas at a
pressure of about 10mm Hg and a small amount of sodium. Inner U tube is well
insulated in order to conserve the heat required to vaporize sodium.
The sorting is effected by means of high leakage autotransformer,

which delivers an open circuit voltage of about 450-480 V, which is sufficient to
initiate the discharge through the neon gas. After a few minutes, the heat
discharge through the neon gas becomes sufficient to vaporize sodium; the lamp
starts its operation, emitting yellow light. The static capacitor improves the P.F
of the circuit
Procedure:
1. Switch on the sodium lamp and wait until red light disappears.
2. Focus on telescope and adjust the collimator so that it gives parallel rays
of light
3. Adjust width of screen by its tangential screen so that one looking

through it look as fine as possible.
4. Place grating on turn table.
5. Adjust telescope in front of collimator lens and observe directly in middle

of crosswire by adjusting telescope with a fine adjustment screen.
6. After these adjustments fix the turn table
7. Bring telescope in front of uled surface of grating.
8. Note the position of telescope when it is in front of collimator position I

this will be initial position reading.
9. Turn the telescope to left and note the reading for first order spectrum.
10.Also find reading when the telescope observes the first order spectrum or
right hand side at R.
Observations:
Sr. Spectrum Direct Reading at Reading at Difference Mea SinӨ λ

# order reading right left n
position
Average value of lambda=__________m
Precautions:
Diagram:
Fig. 6.1 Sodium Lamp
Lab Exercise:
What is the operating temp? of this lamp?

Q.1 And also tell the pressure of mercury?
Which gas we used in this lamp? Which
Q.2 material used for electrodes?
How it hangs vertically or horizontally?
Q.3
What is the life time of this lamp?
Q.4
Q.5 Which color of light it produces?

below:
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EXPERIMENT # 7
DC Motor& Generator
Objectives:
To study commutation process, DC motor & generator working
Apparatus:
1. DC machine
2. Connecting wires
Theory:
A brushed DC motor is an internally commutated electric motor

designed to be run from a direct current power source. When a current passes
through the coil wound around a soft iron core, the side of the positive pole is
acted upon by an upwards force, while the other side is acted upon by a
downward force. According to Fleming's left hand rule, the forces cause a
turning effect on the coil, making it rotate. To make the motor rotate in a
constant direction, "direct current" commutators make the current reverse in
direction every half a cycle (in a two-pole motor) thus causing the motor to
continue to rotate in the same direction.
In electricity generation, an electric generator is a device that

converts mechanical energy to electrical energy. A generator forces electric
charge (usually carried by electrons) to flow through an external electrical
circuit. It is analogous to a water pump, which causes water to flow (but does
not create water). The source of mechanical energy may be a reciprocating or
turbine steam engine, water falling through a turbine or waterwheel, an internal
combustion engine, a wind turbine, a hand crank, compressed air or any other
source of mechanical energy.
The reverse conversion of electrical energy into mechanical energy

is done by an electric motor, and motors and generators have many similarities.
In fact many motors can be mechanically driven to generate electricity, and very
frequently make acceptable generators
Procedure:
1. In this experiment the DC machine is operated as a shunt-wound

machine(separately excited).
2. Set up the apparatus in motor arrangement as shown in the fig 7.1 shunt
wound arrangement.
3. Switch on the POWER button of the power supply.
4. To operate machine in generator mode apply a suitable prime mover for

mechanical energy source.
5. In this experiment we are using another DC machine (motor mode) as

prime mover.
6. Shafts of both machines are coupled mechanically
7. Turn on the prime mover as a result motor will rotate which will act as a
prime mover for other DC machine(generator mode)
8. Connect a DMM on DC machine (generator mode) armature terminals

and set it to DC voltage.
9. Note the generated voltage.
Ciecuit Diagram:
Fig 7.1 DC Motor & Generator
Observations:
Motor speed:_________Rpm
Generated voltage (Generated mode):________V
Lab Exercise:
Why generated voltage in not AC in this

Q.1 case?
Write down the names of common prime
Q.2 movers used in industry?
Why electromagnet is better than peranent
Q.3 magnet?
Write down three methods of controlling
Q.4 speed of DC motor?
Q.5 How can we reverse direction of rotation

of a DC motor?

below:
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EXPERIMENT # 8
Slip Ring with Shorted & Unconnected Rotor Winding
Objectives:
To study and observe working of Slip ring machines with unconnected and
connected rotor windings
Apparatus:
1. Slip ring machine card
2. Lucas-Nulle unitrain module
3. PC
4. Connecting wires
Theory:
8.1:Induction Motor Types
1. squirrel-cage 2.Slip Ring
In induction machines a distinction is drawn between machines with squirrel-

cage rotors and those with slip-ring rotors. In terms of physical response and in
the design of the stator, slip-ring rotor machines do not differ in any way from
squirrel-cage.
However it is the rotors of the machines which are different, having
considerable dissimilarities in their construction.
8.2:Principal differences between slip-ring rotor and squirrel-cage

machines
A squirrel-cage rotor (left) has a winding in the form of individual rods, which
are connected at both ends via, short-circuit rings. There is no other way to
access the rotor winding from outside and thus no possibility of influencing the
rotor's operating response as shown in figure 8.1. A slip-ring rotor, like its stator,
is equipped with a "real" three-phase winding which is connected in the
standard three-phase star configuration. These windings are represented in the
diagram as three single windings shown in three different colors one color per
winding. The ends of the rotating three-phase windings are connected to the
slip-rings, on which carbon brushes impinge. The terminals of the carbon
brushes are connected up to terminal panel. Thus the rotor winding ends, as well
as the ends of the stator winding, are accessible at the terminal for connection to
a circuit. The operating response of the rotor can be modified as a function of
and in accordance with the circuit configuration.
Fig 8.1 Induction Motor Types
Normally the rotor winding is completely short-circuited after run-up using

resistors.
The following holds true for the speed in all induction machines:
where:
p = number of pole pairs
f1 = frequency of the stator voltage being applied
s = slip
It implies that the following means can be used to change the motor's speed:
 Change the number of pole pairs p, e.g. in pole-changing motors
 Change the frequency f1 of the motor's supply voltage
 Modify the slip s by changing the stator voltage
 Modify the slip s by making changes to the rotor
i)Slip ring Machines with Unconnected rotor windings
Procedure:
1. In this experiment the response of the slip-ring rotor machine is

demonstrated with disconnected rotor windings. Set up the apparatus
as shown in figure 8.2.
2. Open the virtual instrument 3-phase Power Supply from the

Instruments Power Supplies menu. Carry out the following settings:
3. U = 11 V
4. f = 50 Hz
5. Press the POWER button
Circuit Diagram:
Fig 8.2 Slip Ring machines with unconnected rotor windings
Observations:
Q. What do you observe?
1. Rotor rotates slowly
2. Rotor does not rotate
3. Rotor s arts rotating
Q. What is the reason for this response?
1. No current can flow due to the disconnected rotor winding. Since no

current is flowing, there can be no torque generated and thus no rotation.
2.The short circuit interferes with the operation
3. Due to the short-circuit current a magnetic field arise which in conjunction

with the external magnetic field generates a torque.
ii)Slip ring Machines with shorted rotor windings:
Procedure:
1. In this experiment the response of the slip-ring rotor machine is

demonstrated with disconnected rotor windings. Set up the apparatus
as shown in figure 8.3.
2. Open the virtual instrument 3-phase Power Supply from the

Instruments Power Supplies menu. Carry out the following settings:
3. U = 11 V
4. f = 50 Hz
5. Press the POWER button
Circuit Dagram:
Fig 8.3 Slip Ring Machine with Shorted rotor windings
Observations:
Q. What do you observe?
1. Rotor rotates slowly
2. Rotor does not rotate
3. Rotor s arts rotating
Q. What is the reason for this response?
1. No current can flow due to the disconnected rotor winding. Since no

current is flowing, there can be no torque generated and thus no rotation.
2.The short circuit interferes with the operation
3. Due to the short-circuit current a magnetic field arises which in

conjunction with the external magnetic field generates a torque.
Lab Exercise:
Task 8.1:Make a comparison between unconnected rotor winding and shorted

rotor winding and also tell the reason for different response.
Conclusions: Describe your Comments in the space given below.
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EXPERIMENT # 9
PCB Designing
Objectives:
To learn PCB Designing and to design a sample circuit on a PCB SHEET
Apparatus:
1. PCB Sheet
2. Permanent marker
3. DMM
4. FeCl 3 Solution
Theory:
A basic PCB starts with a copper-clad fiberglass material or thin copper sheets
adhered to either side of the board. With a multilayer board (a board with more
than two copper layers), a piece of Pre-Preg may be placed between these cores
to create one solid board with several copper layers. Pre-Preg is made of
material similar to the core with additional adhesive that will adhere it to the
layer above and below.
Procedure:
1. Draw a layout of the circuit without components shown in figure 9.1 on a

rough sheet.
2. Implement this layout on copper side of PCB using a permanent marker
3. Place the PCB sheet in ferric chloride solution
4. Wait until Copper from PCB sheet is being removed
5. Use DMM to check connectivity of the circuit.
6. Now use a scratching material to scratch the permanent marker.
7. Drill the holes on PCB for placing components terminals.
8. Insert the components and troubleshoot the circuit.
Precautions:
3. Don’t touch ferric chloride solution with hand
Diagram:
Fig. 9.1 Sample Circuit
Lab Exercise:
Task 9.1: Design the same PCB sheet using proteus ARES.
Task 9.2: Do PCB designing for a Fire alarm circuit.
Conclusions: Describe your Comments & observations in the space given

below.
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EXPERIMENT # 10
Repairing of Home Appliances

Objectives:
To study repairing of home appliances such as Heater, Electric iron and fans etc
Apparatus:
1. Electric Heater
2. Fan
3. Electric Iron
4. Screw driver
5. Pliers
6. Tester
Theory:
10.1:Heater
Electric Heater – consists of cast iron plate housing. The heating

element of micron, wire embedded in heat resistant insulated material likes a
fire clay element. It takes less time to get heated up then retain heat for a longer
time after switching off the power supply. The usual rating of hot plate is 1KW
or 2 KW.
10.1.1:Types
Heaters are of two types –
Table heater: It consists of four parts: base of the heater, the heating plate
(made up of cast iron), circular in shape made up of china clay in which
grooves are provided.
Room Heater: It consists of stand made up of casted MS steel reflector

with metal plate to reflect more heat and connection of brass and copper.
10.2: Fan
A fan consists of a rotating arrangement of vanes or blades which

act on the air. Usually, it is contained within some form of housing or case. This
may direct the airflow or increase safety by preventing objects from contacting
the fan blades. Most fans are powered by electric motors, but other sources of
power may be used, including hydraulic motors and internal combustion
engines and solar power.
10.3: Electric Iron
A clothes iron, also referred to as simply an iron, is a small

appliance used in ironing to remove wrinkles from fabric. Ironing works by
loosening the ties between the long chains of molecules that exist in polymer
fiber materials. With the heat and the weight of the ironing plate, the fibers are
stretched and the fabric maintains its new shape when cool.
Procedure:
a. Heater:
1. If a shirt circuit occurs switch off the main supply and try to find out the
short circuit and remove it out.
2. If defect is found in plug replace the plug.
3. If chang in length occurs, check the length of the wire.
b.Fan:
1. If fan does not work even after the supply is on check for switch socket
or replace the fan capacitor..
c.Iron:
1. If iron gives shock due to mica part of the element, may get short
circuited.Repair the element to check the contact strip.
2. Iron does not work after the supply is on, there must be damage of supply
if somewhat circuit is open.
Precautions:
1. Be careful and attentive while working on appliances.
2. Use proper tools for each operation
Diagram:
Fig. 10.1 Home Appliances
Lab Exercise:
Q.1 What material we used in heating element

of heater?
Q.2 What is resistance of heating element?
Q.3 What is the voltage of Hot plate in heater?

What are the types of heaters?
Q.4
What is the plating material on reflection of
Q.5 room heater?
What is the rating of ceiling fan?
Q.6
What is the insulating material in iron?
Q.7
Which motor is used in fan?
Q.8
Q.9 What is the function of thermostat in iron?
Q.1 Why Capacitor is used in fans?

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EXPERIMENT # 11
Transformer Winding
Objectives:
To study and make transformer winding.
Apparatus:
1. Bobbin 1.5 x 1 inches
2. Wire 24 SWG
3. Wire 40 SWG
4. E&I strips
5. Clamps
Theory:
A transformer is a device that transfers electrical energy from one

circuit to another through inductively coupled conductors—the transformer’s
coils. A varying current in the first or primary winding creates a varying
magnetic flux in the transformer’s core and thus a varying magnetic field
through the secondary winding. This varying magnetic field induces a varying
electromotive force (EMF), or “voltage”, in the secondary winding.
Procedure:
1. Take bobbin of dimensions 1.5x1 inches.
2. Wound the wires on bobbin.
3. Firstly wound 24 SWG wire and then 40 SWG wire take out both wire
terminals
4. The primary consists of many turns of relatively small wire. The wire is
coated with varnish so that each turn of the winding is insulated from
every other turn. In a transformer designed for high-voltage applications,
sheets of insulating material, such as paper, are placed between the layers
of windings to provide additional insulation.
5. When the primary winding is completely wound, it is wrapped in

insulating paper or cloth. The secondary winding is then wound on top of
the primary winding. After the secondary winding is complete, it too is
covered with insulating paper.
6. Next, the E and I sections of the iron core are inserted into and around the
windings as shown in fig 11.1.
7. Now place clamps and screw it to provide tight packing.
8. The leads from the windings are normally brought out through a hole in
the enclosure of the transformer. Sometimes, terminals may be provided
on the enclosure for connections to the windings. The figure shows four
leads, two from the primary and two from the secondary. These leads are
to be connected to the source and load, respectively.
Precautions:
1. Be careful and attentive while working.
2. Use proper tools for each operation.
Diagram:
Fig. 11.1 Transformer Winding
Lab Exercises:
Q. Which transformer windings are

1 connected to an ac source voltage and
to a load, respectively?
Q. A transformer designed for high-

2 voltage applications differs in
construction in what way from a
transformer designed for low-voltage
applications?
Q. How secondary voltage can be

3 increased?
Q. What are the two main types of cores

4 used in transformers?
Q. Write down the losses that effect
5 transformer performance?

below:
Name
Reg. #
Marks
EXPERIMENT # 12
Layout on Metal Sheet

Objectives:
To prepare layout on a metal sheet by marking and prepare rectangular tray
Apparatus:
6. G.I. (galvanized iron) sheet 26 SWG.

7. Scale
8. Scriber
9. Snip
10. Mallet
11. Surface plate
12. Pipe stake
13. Combination pliers
14. Bench vice
15. Ball pen
16. Hammer
Theory:
Sheet metal is simply metal formed into thin and flat pieces. It is one of
the fundamental forms used in metalworking, and can be cut and bent into a
variety of different shapes. Countless everyday objects are constructed of the
material. Thicknesses can vary significantly, although extremely thin
thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in)
are considered plate.
Procedure:
9. Sheet of required size is cut and smoothened by using mallet.
10.Layout of the tray is drawn on the sheet as per pattern using the scriber.
11. Four corners are cut as per marking using straight snip.
12. Edges are folded to make the beading on all four sides.
13. Bending of all four sides are done at right angles opposite the beading
and bend corners using mallet.
14. Hammer is used to give it a good shape.
15. Then the tray is finished.
Precautions:
3. Be careful and attentive while working on metal sheet.
4. Wear, apron, shoes, gloves and tight fitted clothes.
Diagram:
Fig. 12.1 Rectangular Tray
Lab Exercises:
Task 12.1: Repeat the same procedure and try to make a Metallic octagon of
each side length 3cm.

below:
Name
Reg. #
Marks
EXPERIMENT # 13
Drilling
Objectives:
To mark punch and drill holes on a metal sheet.
Apparatus:
1. Drilling machine
2. drill chuck
3. machine vice
4. twist drill bits
5. by square
6. hacksaw
7. centre punch
8. hammer
Theory:
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole
in solid materials. The drill bit is a multipoint, end cutting tool. It cuts by
applying pressure and rotation to the work piece, which forms chips at the
cutting edge.
Procedure:
1. A flat piece of required dimension is to be cut using hacksaw.
2. Chalk solution is applied on the surface of metal and left to dry.
3. Dried metal piece is marked as per dimension given in the drawing using
steel rule and scriber.
4. Centre of the hole is marked using centre punch and hammer.
5. Job is clamped in the vice of drilling machine keeping the marked surface
upward and enlarges the centre of the hole using centre drill in the
machine.
6. The centre drill is taken out and the drills of required sizes are fitted in
the drill chuck of the machine and drill the job.
Precautions:
1. Feed to be applied slowly in the beginning
2. Heavy feed may damage the drill bits. Don’t use too much pressure on the
feed handle
3. Coolant to be used.
4. Hand gloves, apron and shoes must be used while working
5. Work piece should be firmly tightened in the vice of the machine.
Diagram:
Fig. 13.1 Drilling
Lab Exercise:
Task 13.1: Repeat the same procedure and drill 4 holes of different diameter on
work piece.

below:
Name
Reg. #
Marks
EXPERIMENT # 14
Wielding
Objectives:
To prepare Joints for butt- welding and lap welding.
Apparatus:
1. Scale
2. Scriber
3. Hand hack saw
4. Chisel
5. Welding machine
6. Eye shield
7. Gloves
8. Wire brush
9. Chipping hammer
10.Welding rod
Theory:
Welding is a fabrication or sculptural process that joins materials,

usually metals or thermoplastics, by causing coalescence. This is often done by
melting the work pieces and adding a filler material to form a pool of molten
material (the weld pool) that cools to become a strong joint, with pressure
sometimes used in conjunction with heat, or by itself, to produce the weld.
Butt welds are welds where two pieces of metal are joined at
surfaces that are at 90 degree angles to the surface of at least one of the other
pieces. These types of welds require only some preparation and are used with
thin sheet metals that can be welded with a single pass. Common issues that can
weaken a butt weld are the entrapment of slag, excessive porosity, or cracking.
A lap joint is a technique for joining two pieces of material by

overlapping them. A lap may be a full lap or half lap. In a full lap, no material is
removed from either of the members to be joined, resulting in a joint which is
the combined thickness of the two members. In a half lap joint, material is
removed from each of the members so that the resulting joint is the thickness of
the thickest member. Most commonly in half lap joints, the members are of the
same thickness and half the thickness of each is removed.
Procedure:
a.Butt Joint:
1. Two pieces are cut to size and surfaces are cleaned.
2. One edge of both the pieces is prepared at 45 degree angler for making V-
groove using file.
3. Electrode is held in electrode holder and earth clamp is clamped to the

work piece.
4. Pieces are positioned properly butting each other and tack weld in done at
two end points.
5. 2-3 mm spark gap is maintained and continuous welding is done slowly.
6. Slag is removed using chipping hammer and the weld is cleaned using
wire brush.
b.Lap Joint:
1. Two pieces are cut to size and surfaces to be welded are cleaned properly.
2. Electrode is held in electrode holder and earth clamp is clamped to be

work piece.
3. The pieces are positioned overlapping each other for lap joint and tack
weld is done at two end points.
4. 2-3 mm spark gap is maintained and welding is done smoothly.
5. Slag is removed using chipping hammer and weld is cleaned using wire
brush.
Precautions:
1. Be careful and attentive while working on metal sheet.
2. Wear, apron, shoes, gloves and tight fitted clothes.
4. During welding don’t see the welding light rage directly without the goggles
face shield
5. Do not cool the welding piece in water.
6. Do not keep electrode holder on the welding machine.
7. No inflammable material should be present in welding shop
Diagram:
Fig. 14.1 Lap & Butt Joints
Lab Exercise:
Task 14.1: Repeat the same procedure without clamping earth clamp to the
work piece and find out what happens.

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EE 101 ELECTRICAL WORKSHOP PRACTICE LAB MANUAL

ELECTRICAL WORKSHOP PRACTICE

EXPERIMENT EXPERIMENT TITLE Page

Introduction & Usage of Tools

Basic electric and workshop tools

or plastic handle and a blade of high carbon steel.

A mallet is a kind of hammer, usually of rubber, or sometimes wood smaller

1.2: Electrical Tools

Known as the Miniature Circuit Breaker Box.

METAL CONDUIT PIPE WITH JUNTION BOX:

Hollow metallic pipe bend to an angle of 90° to allow smooth movement of

PVC CASING AND LAPPING:

BATTEN LAMP HOLDER:

Mainly used to hold electric bulbs and lamps.

SWITCH BOARD WITH SWITCHES:

1. SOCKET OUTLETS: it is a type of electrical material through which

2. TWO WAY SWITCH: it is mainly used in staircase wiring to either on or

3. ONE-WAY SWITCH: it is a device used to switch on lights of 6A.

7/29 SWG (POWER WIRE):

3/29 SWG (PHASE WIRING):

Mostly used for house wiring purposes.

3/29 SWG (NEUTRAL WIRE):

It is also used for house wiring purposes.

It is used for earthing.

What is the function of hack saw?

Q.2 How many types of pliers we used?

Q.3 What is the function of chisel?

Q.4 What is the function of screwdriver?

Q.5 Why we use flexible wires?

Conclusions: Write your observations & comments in the space provided

T-Joint & Straight Joint

3. 3/29 SWG wires

It is used to take connections from a horizontal line and it is also

it is used to increase the length of the 3 standard wires

1. Take 2 horizontal and vertical lengths of wires 30cm and 20cm

2. Remove the insulation of taping vertical length of 7.5cm

3. Remove the insulation of straight length middle portion

4. Remove the insulation of 12mm on each side of the base wire.

7. Round off the conductor with the help of a plier.

1. Cut two pieces of cable of nearly the same length.

1. Tools should be used carefully

2. Fitting should be tightly fitted

3. Connection should be tight.

4. Wire should be on the conduit, power gripped properly

Fig. 2.1 T-Joint

Fig.2.2 Straight Joint

Why we make a T joint?

Q.4 What is the main precaution to make the

Which joint is used for Fan connection?

Conclusions: Write your observations & comments in the space provided

1. 3/29 SWG wires

3. two way switch

6. strips and pliers.

It is that wiring which makes use of 2 switches to operate bulb at

1. Plan the wiring and casing according to the circuit diagram.

7. Use PVC case wiring to cover expose wiring.

8. Switch ON and OFF the two switches alternatively to the bulb.

1. Tools should be used carefully

2. Fitting should be tightly fitted