QPEO2/033

Performing Engineering
Operations

Wiring and testing electrical

equipment and circuits
1
Question 1

• Work in compliance with HSWA

• PUWER, EAWR, PPEWR, BS7671

• Correct PPE, tools and appropriate test equipment for the

task eg. PAT ‘tester’, test leads to (GS38)

• Safe use of equipment and tools

• Correct documentation and forms

• Adhere to the correct codes of practice

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Question 2
• Live parts may exist
• Sharp edges to casings and enclosures
• Defective plugs and connections
• Damage apart from light scuffing to the cable sheath
• Is the plug undamaged?
• Are there any inadequate joints in the lead?
• How is the cable sheath secured in the equipment/plug?
• What condition is the equipment to be used in?
• Does the lead and tool meet the requirements of
the environmental conditions?
• Is there any damage to the equipment with screws
missing or vents blocked?
• Is there any evidence of overheating?
3
Question 2

• Sharp tools for stripping cable

insulation, knives, cable croppers

• Use correct tools for the job – NOT

Stanley knife!!

• Use tools with appropriate caution

4
Question 2

• Ensure the correct tools are ready for

the job and in good condition and
working order

• Use tools in the correct safe manner

5
Question 3
Wear appropriate PPE whilst carrying
out the task in order to minimise possible
injury.

The job will be carried out more efficiently

if all tools and materials required are readily
at hand and not hidden under an untidy
work area!

Write a paragraph on each of the

above to answer question 3…
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Question 4
Hazardous voltages!!!!!!

Generally voltages greater than 50Volts a.c. or 120V d.c. are

considered hazardous under normal conditions.

eg. 230V AC, 400V AC

More specifically, peak voltage greater than 42.4V is hazardous;

voltage less than or equal to 42.4V, or SELV (safety extra-low
voltage), is non-hazardous.

It is difficult to know exactly when electricity can cause serious injury

or be fatal. Contact for only 1 to 3 seconds with currents of only 6 to
200mA can cause electrocution by disrupting the normal rhythm of
heart muscles, resulting in fibrillation and leading to DEATH!!!

It all depends upon RESISTANCE!!!!!!!!!

7
Question 4
Hazardous voltages!!!!!!

It’s not volts that kill it’s the Amps…. you only need 50mA across your
heart to kill you. There is enough in a 9v battery to kill you under the
right conditions!

Voltage just pushes the current through you, the higher the voltage
the easier the path through your body, it all depends upon your
resistance!

If you touch a 9v battery with your dry finger you won’t feel anything, if
you wet your finger and try again you will get a current flow and you
may feel it tingle? (don’t try this at home) (especially if you have a
pace maker!!!!)

8
Question 4

How to recognise a victim of

electric shock????
The main symptom of a victim who has received a severe electric shock
is usually white or very pale blue skin. Another symptom is bluish color to
the membrane inside the person's mouth or under the eyelid, which are
usually pinky in colour. The victim may also have a weak or absent pulse,
burned skin and stiffness of the body. You should not consider this as
rigor mortis. Before you administer first aid you must ensure the victim is
no longer in contact with the power source, or if they are turn the power
source off. If you cannot isolate the power, protect yourself with a dry
insulating material such as dry clothing. With this try to pull, push or roll
the victim. It is important you do not touch the victim. If the victim is
unconscious you should administer artificial respiration/ventilation. The
victim should then be moved to a medical facility and be observed for
several hours.
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Question 5
How to reduce the risks of Phase
to Earth electric shock????

10
Question 5
How to reduce the risks of Phase
to Earth electric shock????
RCD – Residual Current Device
Earthing & bonding
Basic and Fault Protection
Insulation of live parts
Insulated tools/equipment
Barriers and enclosures
IP ratings
Safe isolation/GS38 test leads
Safe working procedures
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Question 5 cont….

How to reduce the risks of Phase

to Earth electric shock????

Click on the following links!

http://www.hse.gov.uk/pubns/indg354.pdf

http://www.schneider-electric.com.au/documents/electrical-
distribution/en/local/electrical-installation-guide/EIG-F-protection-electrical-
shocks.pdf

12
Question 6

• Use of BS and ISO schematic diagrams

• Block and circuit wiring diagrams

• Standard EN symbols and terminology

• BS7671 Wiring Regulations

13
Question 7

• The basic principles of operation

of equipment are to be able to:

• start
• run
• pause
• stop
• emergency stop!
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Question 8
Cable types and applications!!
• An extensive range of various cable types
and sizes are available for a multitude of
applications
• SWA for outside work where high levels
of mechanical protection is required
• Pyro (MICC) for fire and mechanical
protection
• Fibre optic cables are used for
transmitting data and light
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Question 9

Electrical components – range and

applications!

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Question 9

• Plugs – to connect and disconnect portable

equipment, modular, electronic components,
data, communication and emergency
equipment
• Switches – to switch circuits on and off and
also change direction of motors. Emergency
alarm and firefighters switches
• Sockets – used to plug in portable and
temporary static appliances and equipment via
the use of a plug
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Question 9 continued…

• Lighting & fittings – to supply lighting

and power efficiently, safely and effectively

• Junction boxes – to provide good, safe

and effective cable terminations and joints
also providing basic protection.

Note that JB’s should only be used for where

accessible for maintenance purposes.
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Question 9 continued…
Consumer unit – The part of the fixed electrical installation that
contains the circuit protective devices, either fuses, MCB’s or
RCD’s. The consumer unit is where circuits can be isolated if
necessary by switching off the MCB or removing the fuse for a
circuit. It is used to control and distribute electricity around the
home. It usually contains a main switch, fuses or circuit breakers
and one or more residual current devices.

Relays and solenoids - A relay is an electrically operated switch.

Many relays use an electromagnet to operate a switching
mechanism mechanically, but other operating principles are also
used. Relays are used where it is necessary to control a circuit by
a low-power signal (with complete electrical isolation between
control and controlled circuits), or where several circuits must be
controlled by one signal.
19
Question 9 continued…

Transformers - 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. This effect is called mutual induction.

20
Question 9 continued…
Sensors and actuators
An actuator is a mechanical device for moving or controlling a
mechanism or system. It is operated by a source of energy,
usually in the form of an electric current or hydraulic fluid
pressure, and converts that into some kind of motion.

A sensor is a device that measures a physical quantity and

converts it into a signal which can be read by an observer or by an
instrument. For example, a mercury-in-glass-thermometer
converts the measured temperature into expansion and
contraction of a liquid which can be read on a calibrated glass
tube. A thermocouple converts temperature to an output voltage
which can be read by a voltmeter. For accuracy, most sensors are
calibrated against known standards. A passive infra-red (PIR)
sensor senses movement in the air.
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Question 10
A Fuse is essentially a metal wire or strip that melts when too much current
flows, which interrupts the circuit in which it is connected.
Short-circuit, overload or device failure is often the reason for excessive current.
A fuse interrupts excessive current (blows) so that further damage by
overheating or fire is prevented.
The Wiring regulations define maximum fuse current ratings for particular
circuits. Overcurrent protection devices are essential in electrical systems to
limit threats to human life and property damage.
Fuses are selected to allow passage of normal current and of excessive current
only for short periods of time.
A residual-current device (RCD), similar to a Residual Current Circuit
Breaker (RCCB), is an electrical wiring device that disconnects a circuit
whenever it detects that the electric current is not balanced between the
energized conductor and the return neutral conductor.
Such an imbalance is sometimes caused by current leakage through the body
of a person who is grounded and accidentally touching the energized part of the
circuit. A lethal shock can result from these conditions.
RCDs are designed to disconnect quickly enough to mitigate the harm caused
by such shocks although they are not intended to provide protection against
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overload or short-circuit conditions.
Question 11

• By formal circuit design using BS7671 Wiring

Regulations

• Using tables, cable calculations, current

carrying capacities and volt drop tables

• OPD rating tables and graphs

• Working temperature characteristics and

external influences
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Question 12

• Brick and concrete - screws and plugs

• Plasterboard - plasterboard fixings
• Plasterboard - dryliner screws
• Metal tray - nuts and bolts, cable ties,
uni-strut, cable cleats and clamps
• wood – wood screws

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Question 13

• measurement

• diagrams

• voltage and metal detection

instruments and devices

• thermal imaging devices

25
Question 14

• draw tape

• cable push-pull rods

• cable ties

• stays and clamps

• Yellow 77
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Question 14

• To avoid build up of heat

• Heat cannot dissipate if cables are twisted

or plaited

• Also cables cannot be traced or removed

if necessary

• Cables should be installed untwisted to avoid

friction damage (burning) when being pulled in
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Question 15

• Plugs and socket outlets

• screwed connections
• junction boxes
• clamped and crimped connections
• stuffing glands
• sealed/watertight connections
• SWA and MICC glands, pots and seals
• chocboxes
• soldering
• coloured heatshrink sleeving
• modular and push fit connections
• two-part resins and sealing gels
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Question 16

BS7671 Wiring Regulations are used to select the correct wiring

systems and cables required by referring to the relevant parts,
sections and chapters in order to determine the requirements.
Cable calculations, ambient temperatures, external influences,
voltage, current ratings, resistance and impedance, earthing
systems, protection and isolation are all to be ascertained.
Also Inspection, Testing and Verification requirements can be
found in Part 6 of the regulations.
All inspection and testing procedures are to be carried out in the
correct sequence.

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Question 17

•The current wire identification methods are:

•Inkjet Marking
•Hot Stamp Marking
•Labelling
•Colour coding, Heat Shrink
•Thermal Marking
•Laser Marking
•Coded tabs
•Self adhesive pre-printed cable markers
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Question 18

• crimping tools
• cable stripping tools
• soldering irons and torches
• soldering flux
• gland connecting tools
• pliers & side cutters
• electricians knife
• insulation & continuity tester
31
Question 19

• Visual inspection for cracks, breakages

and exposed parts

• PAT test electrical tools & test equipment

• Check for current labels and dates

• Visually check tools to verify in good order

and condition
32
Question 20

To avoid electric shock and fire hazards

due to poor condition of tools/equipment:
• visual examination for loose or
exposed conductors
• Excessive solder or solder spikes
which may allow short circuits to occur
• strain on terminations
• insufficient slack cable at terminations
• continuity and polarity checks
• insulation checks
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Question 21

Keep test and measuring instruments clean, dry, safe

and well protected in there proper cases or appropriate
carrying case, ensure regular calibration at an
authorised calibration centre and regularly carry out
ongoing self-check calibration against a regular known
source to ensure readings are within
expected/acceptable parameters. Handle carefully and
respectfully, never drop, always use in the correct
manner according to manufacturers instructions and do
not misuse. Ensure that batteries, if applicable, are in
good order, visually inspect to make sure test leads and
probes are in good order with no damage.
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Question 22

• applying approved test

procedures

• the need to use suitably fused

test probes and clips

35
Question 23

Mark up test points using

suitable marking equipment and
codes and symbols with
reference to a related
component list and circuit
diagram.

36
Question 23

Ensure correct polarity!

Check to ensure the positive + and
negative - probes of the test instrument
are connected to the correct terminals
on the components. These should be
marked or identified on the component
itself or by symbols relating to the
circuit diagram.
37
Question 24

By using auto-null feature if present

and if not, by measuring the resistance
of the test instrument test leads and
subtracting this reading from the final
reading obtained.

38
Question 24

By setting the instrument to the desired

setting appropriate to the test being carried
out. There will be standard maximum and
minimum circuit parameters to use as a
guide which can be obtained from the wiring
regulations. Actual readings obtained
should be within these parameters in order
to be deemed satisfactory.

39
Question 25

Earthing and bonding is a critical element in

providing safety to electrical installations.

It’s main function is to reduce to a minimum,

the risks of fire and shock hazard.

It therefore forms the foundation of most

electrical systems, ensuring safety to any
part of the system, whether new or existing
and no matter how large or small.
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Question 25

Earthing and bonding connections must be both

mechanically and electrically secure in order to
reduce loss of continuity.

If loose or corroded connections are present,

good continuity will be lost causing insufficient
circuit protection under fault conditions.
Shock and fire hazards are minimised when
connections are secure, tight and also
mechanically protected against corrosion.

41
Question 26
Loose screw and crimp connections, dry solder joints,
corroded joints, broken terminals, poor insulation.
These problems can be overcome by vividly checking
all connections and component wiring during the
installation and on completion.
Incorrect readings obtained during testing can be
caused by poor installation work and lack of correct
inspection.
Also it should be ensured that test equipment is in
correct working order.
Regular service and calibration of test equipment is
essential. 42
Question 27

• Visually inspect
• check fuses
• continuity of conductors
• insulation resistance
• polarity
• check to verify a supply is present.

43
Question 28

You should act on your own initiative to find, clarify

and evaluate information if you are unsure about
something.

You should also seek help and advice from others.

Seek help and advice from others if a hazard. Eg. a

bear/exposed unprotected live wire or sharp edges
are discovered (remove it if possible or make it safe).

Get help when personally in danger

(for discovery of asbestos, call the HSE).
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Question 29
You should maintain good housekeeping by keeping
your work area neat and tidy, in order to minimise
hazards which could lead to accidents and injury. Also
the loss and misplacement of tools and other items of
equipment will be minimised.
Dispose of waste safely and environmentally. You must
store materials as per manufacturers instructions eg in
clean and dry areas, check all tools before use.
Electrical tools should be PAT tested. It is important to
dispose of waste materials and consumables such as
oils and chemicals because they have potential to cause
fire or explosion.(Dangerous substances and explosive
atmospheres Regulations 2002) Waste electrical and
electronic equipment (WEEE) EU direct 2005. 45
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