ELECTRONIC MECHANIC

NSQF LEVEL - 5

1st Semester
TRADE PRACTICAL

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SECTOR: Electronics and Hardware
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DIRECTORATE GENERAL OF TRAINING

MINISTRY OF SKILL DEVELOPMENT & ENTREPRENEURSHIP
GOVERNMENT OF INDIA

NATIONAL INSTRUCTIONAL
MEDIA INSTITUTE, CHENNAI
(i)
Post Box No. 3142, CTI Campus, Guindy, Chennai - 600 032
Sector : Electronics & Hardware
Duration : 2 - Years
Trade : Electronic Mechanic 1st Semester - Trade Practical - NSQF level 5

Copyright ©2018 National Instructional Media Institute, Chennai

First Edition : August 2018 Copies : 1,000
Second Edition : January 2019 Copies : 3,000

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Rs.320/-
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All rights reserved.

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No part of this publication can be reproduced or transmitted in any form or by any means, electronic or mechanical, including
photocopy, recording or any information storage and retrieval system, without permission in writing from the National
Instructional Media Institute, Chennai.

Published by:
NATIONAL INSTRUCTIONAL MEDIA INSTITUTE
P. B. No.3142, CTI Campus, Guindy Industrial Estate,
Guindy, Chennai - 600 032.
Phone : 044 - 2250 0248, 2250 0657, 2250 2421
Fax : 91 - 44 - 2250 0791
email : chennai-nimi@nic.in, nimi_bsnl@dataone.in
Website: www.nimi.gov.in

(ii)
 FOREWORD

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

The National Instructional Media Institute (NIMI), Chennai, has now come up with instructional material to
suit the revised curriculum for Electronic Mechanic 1st Semester Trade Practical NSQF Level - 5 in
Electronics & Hardware Sector under semester pattern . The NSQF Level - 5 Trade Practical will help the
trainees to get an international equivalency standard where their skill proficiency and competency will be
duly recognized across the globe and this will also increase the scope of recognition of prior learning.
NSQF Level - 5 trainees will also get the opportunities to promote life long learning and skill development.
I have no doubt that with NSQF Level - 5 the trainers and trainees of ITIs, and all stakeholders will derive

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maximum benefits from these IMPs and that NIMI's effort will go a long way in improving the quality of
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Vocational training in the country.
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The Executive Director & Staff of NIMI and members of Media Development Committee deserve appreciation
for their contribution in bringing out this publication.
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Jai Hind
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RAJESH AGGARWAL
Director General/ Addl. Secretary
Ministry of Skill Development & Entrepreneurship,
Government of India.

New Delhi - 110 001

(iii)
 PREFACE

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

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

The trade practical book consists of series of exercises to be completed by the trainees in the workshop.
These exercises are designed to ensure that all the skills in the prescribed syllabus are covered. The trade
theory book provides related theoretical knowledge required to enable the trainee to do a job. The test and

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assignments will enable the instructor to give assignments for the evaluation of the performance of a trainee.
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The wall charts and transparencies are unique, as they not only help the instructor to effectively present a

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topic but also help him to assess the trainee's understanding. The instructor guide enables the instructor to
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plan his schedule of instruction, plan the raw material requirements, day to day lessons and demonstrations.
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IMPs also deals with the complex skills required to be developed for effective team work. Necessary care
has also been taken to include important skill areas of allied trades as prescribed in the syllabus.
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The availability of a complete Instructional Media Package in an institute helps both the trainer and
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management to impart effective training.

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

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

R. P. DHINGRA
C h en n a i - 600 032 E X E C U T IV E D IR E C T O R

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 ACKNOWLEDGEMENT

National Instructional Media Institute (NIMI) sincerely acknowledges with thanks for the co-operation and
contribution extended by the following Media Developers and their sponsoring organisations to bring out this
Instructional Material (Trade Practical) for the trade of Electronic Mechanic under Electronics and Hardware
sector.

MEDIA DEVELOPMENT COMMITTEE MEMBERS

Shri. G. Ethirajulu _ Principal (Retd)

MDC Member,
NIMI, Chennai-32.

Shri. D.S. Varadarajulu _ DD/Principal (Retd)

MDC Member,

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NIMI, Chennai-32.
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Shri. V. Gopalakrishnan
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Co-ordinator, NIMI, Chennai - 32

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NIMI records its appreciation for the Data Entry, CAD, DTP operators for their excellent and devoted services in
the process of development of this Instructional Material.
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NIMI also acknowledges with thanks the invaluable efforts rendered by all other NIMI staff who have contributed
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towards the development of this Instructional Material.

NIMI is also grateful to everyone who has directly or indirectly helped in developing this Instructional Material.

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 INTRODUCTION
TRADE THEORY

The manual of trade theory consists of theoretical information for the First Semester couse of the Electronic
Mechanic Trade. The contents are sequenced according to the practical exercise contained in the manual on
Trade practical. Attempt has been made to relate the theoretical aspects with the skill covered in each exercise
to the extent possible. This co-relation is maintained to help the trainees to develop the perceptional capabilities
for performing the skills.

The Trade Theory has to be taught and learnt along with the corresponding exercise contained in the manual
on trade practical. The indicating about the corresponding practical exercise are given in every sheet of this
manual.

It will be preferable to teach/learn the trade theory connected to each exercise atleast one class before
performing the related skills in the shop floor. The trade theory is to be treated as an integrated part of each
exercise.

The material is not the purpose of self learning and should be considered as supplementary to class room
instruction.

TRADE PRACTICAL

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The trade practical manual is intented to be used in workshop . It consists of a series of practical exercies to
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be completed by the trainees during the First Semester course of the Electronic Mechanic Trade

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supplemented and supported by instructions/ informations to assist in performing the exercises. These
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exercises are designed to ensure that all the skills in the prescribed syllabus are covered.
The manual is divided into three modules. The distribution of time for the practical in the three modules are
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given below.
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Module 1 Basic Workshop Practice 13 Exercises 75 Hrs

Module 2 Basic Electricity 22 Exercises 100 Hrs
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Module 3 Measuring Technique 05 Exercises 50 Hrs

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Module 4 Soldering and De-Soldering 06 Exercises 25 Hrs

Module 5 Active and Passive component 17 Exercises 75 Hrs
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Module 6 Rectifiers 10 Exercises 50 Hrs

Module 7 Basic Computer 23 Exercises 125 Hrs
Module 8 IC Regulators 05 Exercises 25 Hrs
Total 101 Exercises 525 Hrs

The skill training in the computer lab is planned through a series of practical exercises centred around some
practical project. However, there are few instance where the individual exercise does not form a part of project.

While developing the practical manual a sincere effort was made to prepare each exercise which will be easy
to understand and carry out even by below average traninee. However the development team accept that there
if a scope for further improvement. NIMI, looks forward to the suggestions from the experienced training faculty
for improving the manual.

(vi)
 CONTENTS

Exercise No. Title of the Exercise Page No.

Module 1: Basic workshop Practice

1.1.01 Visit various sections of the ITI and identify the location of various
installations 1

1.1.02 Identify Safety Sign for danger warning, caution & personal safety message 2

1.1.03 Use of Personal Protective Equipment (PPE) 7

1.1.04 Practice elementary First Aid 9

Artificial respiration - Nelson’s arm - lift back - pressure method 10

Artificial respiration - Schafer’s method 11

Artificial respiration - mouth to mouth method 12

1.1.05 Preventive measure for electrical accidents & steps to be taken in

such accidents 15

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1.1.06 Use of Fire Extinguisher 16

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1.1.07
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Identify, the different hand tools 19
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1.1.08 Selection of proper tools for operation and precautions in operation 22

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1.1.09 Care and maintenance of trade tools 23

1.1.10 Practice safety precautions while working in fitting jobs 24

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1.1.11 Workshop Practice on filing and hacksawing 26

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1.1.12 Practice simple sheet metal works, fitting and drilling 28

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1.1.13 Making an open box from metal sheet 30

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Module 2: Basic Electricity

1.2.14 Identify the phase and neutral and earth on power socket use testers to
monitor AC power 32

1.2.15 Construct a test lamp and use it to check mains healthiness 34

1.2.16 Measure the voltage between phase and ground and rectify earthing 35

1.2.17 Identify and test different AC mains cables 36

1.2.18 Prepare terminations, skin the electrical wires / cables using wire stripper
and cutter 38

1.2.19 Measuring the gauge of the wire using SWG and outside micro meter 44

1.2.20 Refer table and find current carrying capacity of wires 47

1.2.21 Crimping the lugs to wire end 50

1.2.22 Measure AC and DC Voltage using multi meter 53

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Exercise No. Title of the Exercise Page No.

1.2.23 Identify the type of meters by dial and scale marking / symbols 55

1.2.24 Demonstrate various analog measuring instruments 59

1.2.25 Find the minimum and maximum measurable range of the meter 63

1.2.26 Carryout Mechanical Zero setting of a meter 64

1.2.27 Check the continuity of wires, meter probes and fuse etc 66

1.2.28 Measure voltage and current using Clamp meter 68

1.2.29 Identify the +ve and -ve terminals of the battery 71

1.2.30 Identify the rated output voltage and Ah capacity of given battery 72

1.2.31 Measure the voltages of given cells / battey using Analog / Digital Multimeter 73

1.2.32 Charge and discharge the battery through load resistor 76

1.2.33 Maintain the Secondary Cells 80

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1.2.34 Measure the specific gravity of electrolyte using hydro meter 83

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1.2.35 Test a battery and verify whether the battery is ready for use or
needs recharging
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Module 3: Measuring Technique

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1.3.36 Use the multimeter to measure the various functions (ACV, DCV,
DCI, ACI, R) 86
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1.3.37 Identify the different types of meter for measuring AC & DC parameters 93
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1.3.38 Identify the different controls on the CRO front Panel and Observe the
function of each control
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99
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1.3.39 Measure VDC, VAC, time period using CRO sine wave Parameters 103

1.3.40 Identify the different controls on the function generator front panel and
observe the function of each controls 107

Module 4: Soldering & Desoldering

1.4.41 Practice soldering on different electronic components, small transformer

and lugs 111

1.4.42 Practice soldering on IC bases and PCBs 113

1.4.43 Practice de-soldering using pump and wick 115

1.4.44 Join the broken PCB track and test 118

1.4.45 Identify and use SPST, SPDT, DPST DPDT,tumbler. push button, toggle ,
piano switches used in electronic industries 120

1.4.46 Make a panel board using different types of switches for a given application 122

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Exercise No. Title of the Exercise Page No.

Module 5: Active and Passive components

1.5.47 Identify the different types of Active electronics components 123

1.5.48 Measure the resistor value by colour code and verify the same by
measuring with Multi meter 126

1.5.49 Identify resistors by their appearance and check Physical defects 129

1.5.50 Identify the power rating of carbon resistors by their size 131

1.5.51 Practice on measurement of parameters in combinational electrical circuit

by applying ohm’s law for different resistor values and voltage sources 133

1.5.52 Verify measurement of current and voltage in electrical circuits to

Kirchhoff’s Law 135

1.5.53 Verify laws of series and parallel circuits with voltage source in different
combinations 139

1.5.54 Measure the resistance, voltage, current through series and parallel
connected network using Multimeter 141

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1.5.55
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Identify different Inductors and measure the values using LCR meter 147
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Identify the different capacitors and measure capacitance of various
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capacitors using LCR meters 150

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1.5.57 Identity and test the Circuit breaker and other protective devices 153

1.5.58 Dismantle and identify the different parts of a Relay 155

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1.5.59 Construct and test of timer relay using IC 555 156

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1.5.60 Connect a Contactor in a circuit and test for its working 157
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1.5.61 Construct and test RC-time constant circuit 160

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1.5.62 Construct a RC differentiator circuit and convert triangular wave into

square wave 161

1.5.63 Construct and test Series and Parallel resonance circuit 163

Module 6: Rectifiers

1.6.64 Identify different types of diode, diode modules and their specifications 165

1.6.65 Test the given diode using Multimeter and determine forward to reverse
resistance ratio 167

1.6.66 Measure the voltage and current through a diode in a circuit and verify its
forward characteristics 170

1.6.67 Identify different types of Transformers and test 173

1.6.68 Identify the Primary and Secondary Transformer windings and test
the polarity 178
1.6.69 Construct and test a Half-wave, Full wave and Bridge rectifier circuit 179

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Exercise No. Title of the Exercise Page No.

1.6.70 Measure ripple voltage, ripple frequency and ripple factor of rectifiers for
different load and filter capacitors 183
1.6.71 Identify and test Zener diode 185

1.6.72 Construct and test Zener based voltage regulator circuit 187

1.6.73 Calculate the percentage regulation of Regulated power supply 189

Module 7: Basic Computer

1.7.74 Identify various indicators, cables, connectors and ports on the

computer cabinet 191

1.7.75 Demonstrate various parts of the system unit and motherboard components 197

1.7.76 Identify various computer peripherals and connect it to the system 199

1.7.77 Disable certain functionality by disconnecting the concerned

cables SATA / PATA 201

1.7.78 Replace the CMOS battery and extend a memory module 203

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1.7.79 Test and Replace the SMPS 206

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1.7.80 Replace the given DVD and HDD on the system 207
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1.7.81 Dismantle and assemble the desktop computer system 209

1.7.82 Boot the system from Different options 211

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1.7.83 Install OS in a desktop computer 216

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1.7.84 Install a Printer driver software and test for print outs 223
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1.7.85 Install antivirus software, scan the system and explore the options in the
antivirus software 232
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1.7.86 Install MS office software 237

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1.7.87 Create folder and files, draw pictures using paint 240

1.7.88 Explore different menu/tool/format/status bars of MS word and practice

the options 248

1.7.89 Explore different menu/tools/format/status bars of Ms excel and practice

the options 253

1.7.90 Prepare power point presentation on any three known topics with various
design, animation and visual effects 259

1.7.91 Convert the given PDF File into Word file using suitable software 267

1.7.92 Browse search engines, create email accounts, practice sending and
receiving of mails and configuration of email clients 270

1.7.93 Identify different types of cables and network components e.g. Hub, switch,
router, modem etc 282

1.7.94 Prepare terminations, make UTP and STP cable connectors and test 285

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

1.7.95 Connect network connectivity hardware check for its functioning 289

1.7.96 Configure a wireless Wi-Fi network 293

Module 8: IC Regulators

1.8.97 Construct and test a +12V fixed voltage regulator 296

1.8.98 Identify the different types of fixed +ve and -ve regulator IC’s and the
different current ratings 298

1.8.99 Identify different heat sinks for IC based regulators 301

1.8.100 Observe the output voltage of different IC723 metal / plastic type and
IC 78S40 regulators by varying the input voltage with fixed load 303

1.8.101 Construct and test a 1.2V-30V variable output regulated power supply
using IC LM317T 305

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 ASSESSABLE / LEARNING OUTCOME

On completion of this book you shall be able to

• Apply safe working practices.

• Perform basic workshop operations using suitable tools for fitting,
riveting, drilling etc. observing suitable care & safety.
• Select and perform electrical/electronic measurement of single
range meters and calibrate the instrument.
• Test & service different batteries used in electronic applications
and record the data to estimate repair cost.
• Plan and execute soldering & de-soldering of various electrical
components like Switches, PCB & Transformers for electronic

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circuits.
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• Test various electronic components using proper measuring
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instruments and compare the data using standard parameters

• Assemble simple electronic power supply circuit and test for
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functioning.
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• Install, configure, interconnect given computer system(s) and

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demonstrate & Utilize application packages for different

applications.
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• Construct, test and verify the input/output characteristics of

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various analog circuits.

• Plan and construct different power electronic circuits and analyse
the circuit functioning.
• Select the appropriate opto electronic components and verify the
characteristics in different circuits.

(i)
 SYLLABUS FOR ELECTRONIC MECHANIC TRADE
FIRST SEMESTER Duration: 6 Months

Week Professional Skills Professional Knowledge

No. Learning Outcome (Trade Practical) with Indicative (Trade Theory)
hrs.

• Apply safe Trade and Orientation Familiarization with the working

1
working 1. Visit to various sections of the of Industrial Training Institute
practices institute and identify location system.
of various installations. (5 hrs) Importance of safety and
2. Identify safety signs for danger, precautions to be taken in the
warning, caution & personal industry/shop floor.
safety message. (3 hrs.) Introduction to PPEs.
3. Use of personal protective Introduction to First Aid.
equipment (PPE). (5 hrs) Response to emergencies e.g.
4. Practice elementary first aid. power failure, fire, and system
(5 hrs) failure.
5. Preventive measures for Importance of housekeeping &
electrical accidents & steps to good shop floor practices.
be taken in such accidents. (2 Occupational Safety & Health:
hrs) Health, Safety and Environment

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6. Use of Fire extinguishers. (5 guidelines, legislations &
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hrs) regulations as applicable.

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• Perform basic Hand tools and their uses Identification, specifications, uses
2-3
workshop 7. Identify the different hand and maintenance of commonly
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operations using tools. (5 hrs) used hand tools.

suitable tools for 8. Selection of proper tools for State the correct shape of files for
fitting, riveting, operation and precautions in filing different profiles.
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drilling etc operation. (7 hrs) Riveting of tags and lugs, cutting

9. Care & maintenance of trade and bending of sheet metals,
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observing
suitable care & tools. (8 hrs) chassis and cabinets.
safety 10. Practice safety precautions
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while working in fitting jobs.

(10 hrs)
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11. Workshop practice on filing

and hacks awing. (5 hrs)
12. Practice simple sheet metal
works, fitting and drilling. (5
hrs)
13. Make an open box from metal
sheet. (10 hrs)
4-5 Select and Basics of AC and Electrical Cables Basic terms such as electric
perform 14. Identify the Phase, Neutral and charges, Potential difference,
electrical/ Earth on power socket, use a Voltage, Current, Resistance.
electronic testers to monitor AC power. (6 Basics of AC & DC.
measurement of hrs) Various terms such as +ve cycle, -
single range 15. Construct a test lamp and use ve cycle, Frequency, Time period,
meters and it to check mains healthiness. RMS, Peak, Instantaneous value.
calibrate the (7 hrs) Single phase and Three phase
instrument. 16. Measure the voltage between supply.
phase and ground and rectify Terms like Line and Phase
earthing. (5 hrs) voltage/ currents.
17. Identify and test different AC Insulators, conductors and
mains cables. (7 hrs) semiconductor properties.
18. Prepare terminations, skin the Different type of electrical cables
 electrical wires /cables and their Specifications.
using Types of wires & cables,
wire stripper and cutter. (7 standard
hrs) wire gauge (SWG).
19. Measure the gauge of the Classification of cables
wire according
using SWG and outside to gauge (core size),
micrometer. (5 hrs) number of
20. Refer table and find current conductors, material,
carrying capacity of wires. insulation
(3 hrs) strength, flexibility etc.
21. Crimp the lugs to wire end.
(5 hrs)
22. Measure AC and DC
voltages
using multi meter. (5 hrs)

Select and 23. Identify the type of meters by dial and

6 scale marking/ Single range meters
perform
symbols. (3 Hrs) Introduction to electrical
electrical/
24. Demonstrate various analog and electronic
electronic
measuring Instruments. (3 Hrs) measuring instruments.
measurement of
25. Find the minimum and Basic principle and parts
single range
maximum measurable range of the of simple meters.
meters and

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meter. (3 Hrs) Specifications, symbols
calibrate the
used in dial and their
instrument.
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26. Carryout mechanical zero
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meaning.

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setting of a meter. (5 Hrs)
27. Check the continuity of wires, meter
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probes and fuse etc. (5 Hrs)

28. Measure voltage and current using
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clamp meter. (6 Hrs)

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Test & service Cells & Batteries

7 Cells & Batteries
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different 29. Identify the +ve and -ve Construction, types of

batteries used in terminals of the battery. (2 hrs) primary and secondary cells.
electronic
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30. Identify the rated output Materials used, Specification

applications and voltage and Ah capacity of ofcells and batteries.
record the data
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given battery. (1 hrs) Charging process, efficiency,

to estimate 31. Measure the voltages of the lifeof cell/battery.
repair cost. given cells/battery using Selection of cells / Batteries
analog/ digital multimeter. (3 etc.
hrs) Use of Hydrometer.
32. Charge and discharge the Types of electrolytes used in
battery through load resistor. cells and batteries.
(5 hrs) Series/ parallel connection of
33. Maintain the secondary cells. batteries and purpose of such
(5 hrs) connections.
34. Measure the specific gravity of
the electrolyte using
hydrometer. 3 hrs)
35. Test a battery and verify
whether the battery is ready
for use of needs recharging. (6
hrs)
8-9 • Test various AC & DC measurements Introduction to electrical
electronic 36. Use the multi meter to measuring instruments.
components measure the various functions Importance and classification of
using proper (AC V, DC V, DC I, AC I, R) (8 hrs.) meters.
measuring 37. Identify the different types of meter Forces necessary to work a meter.
instruments and for measuring AC & DC parameters MC and MI meters.
compare the (8 hrs.) Range extension, need of
data using 38. Identify the different controls on the calibration.
standard CRO front panel and observe the Characteristics of meters and
parameter. function of each control (12hrs.) errors in meters.
39. Measure DC voltage, AC Multi meter, use of meters in
voltage, time period using CRO sine different circuits.
wave parameters (10hrs.) Care and maintenance of meters.
40. Identify the different controls on the Use of CRO, Function generator,
function generator front panel and LCR meter
observe the function of each
controls (12 hrs.)

10 • Plan and Soldering/ De-soldering and Different types of soldering guns,

execute Various Switches related to Temperature and
soldering & 41. Practice soldering on different wattages, types of tips.
desoldering electronic components, small Solder materials and their
of various transformer and lugs. (5 hrs) grading. Use of flux and other

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electrical 42. Practice soldering on IC bases materials. Selection of soldering
components like
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and PCBs. (5 hrs) gun for specific requirement.
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Switches, PCB 43. Practice de-soldering using Soldering and De-soldering
& Transformers pump and wick (2 hrs) stations and their specifications.
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for electronic 44. Join the broken PCB track and Different switches, their
circuits. test (3 hrs) specification and usage.
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45. Identify and use SPST, SPDT,

DPST, DPDT, tumbler, push
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button, toggle, piano switches

used in electronic industries (5
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hrs)
46. Make a panel board using
different types of switches for
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a given application (5 hrs)

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Ohm’s law and Kirchhoff’s Law.

11-13 • Test various Active and Passive Components Resistors; types of resistors, their
electronic 47. Identify the different types of construction & specific use,
components active electronic components. colorcoding,
using proper (3 hrs). power rating.
measuring 48. Measure the resistor value by Equivalent Resistance of series
instruments colour code and verify the parallel circuits.
and same by measuring with Distribution of V & I in series
compare the multimeter (3 hrs) parallel circuits.
data using 49. Identify resistors by their Principles of induction, inductive
standard appearance and check physical reactance.
parameter. defects. (2 hrs) Types of inductors, construction,
• Assemble 50. Identify the power rating of specifications, applications and
simple carbon resistors by their size. energy storage concept.
electronic (3 hrs) Self and Mutual induction.
power supply 51. Practice on measurement of Behaviour of inductor at low and
circuit and parameters in combinational high frequencies.
test for electrical circuit by applying Series and parallel combination, Q
functioning. Ohm’s Law for different factor.
resistor values and voltage Capacitance and Capacitive
sources. (9 hrs) Reactance, Impedance.
 52. Measurement of current and
Types of capacitors,
voltage in electrical circuits to
construction,
verify Kirchhoff’s Law (5 Hrs)
specifications and applications.
53. Verify laws of series and
Dielectric constant.
parallel circuits with voltage
Significance of Series parallel
source in different
connection of capacitors.
combinations. (5 hrs)
54. Measure the resistance,
Capacitor behaviour with AC and
Voltage, Current through series
DC. Concept of Time constant
and parallel connected
of a RC circuit.
networks using multi meter (8
Concept of Resonance and its
hrs)
application in RC, RL & RLC
55. Identify different inductors and
series and parallel circuit.
measure the values using LCR
Properties of magnets and their
meter (5 hrs)
materials, preparation of artificial
56. Identify the different
magnets, significance of electro
capacitors and measure
magnetism, types of cores.
capacitance of various
Relays, types, construction and
capacitors using LCR meter (5 hrs)
specifications etc.
57. Identify and test the circuit
breaker and other protecting
devices. (5 hrs)
58. Dismantle and identify the
different parts of a relay. (5 hrs)

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59. Connect a timer relay in a

bl I
circuit and test for its working.
pu M
ish
(3 hrs)
60. Connect a contactor in a circuit
Re NI

and test for its working (2 hrs)

61. Construct and test RC time
be @

constant circuit (4 hrs)

62. Construct a RC differentiator
o ht

circuit and convert triangular

wave into square wave (5 hrs.)
t t rig

63. Construct and test series and

parallel resonance circuit (3 hrs)
No py

14-15 Power Supply Circuits Semiconductor materials,

Co

• Assemble simple
electronic 64. Identify different types of components, number coding
power supply diodes, diode modules and for different electronic
circuit and test their specifications. (5 hrs) components such as Diodes
for functioning. 65. Test the given diode using and Zeners etc. PN Junction,
multi meter and determine Forward and Reverse biasing
forward to reverse resistance of diodes. Interpretation of
ratio. (5 hrs) diode specifications. Forward
66. Measure the voltage and current and Reverse voltage.
current through Packing styles of diodes.
67. Identify different types of
transformers and test. (3 hrs) Different diodes, Rectifier
68. Identify the primary and configurations, their
secondary transformer windings efficiencies, Filter
and test the polarity (2 hrs) components and their role in
69. Construct and test a half wave, reducing ripple. Working
full wave and Bridge rectifier principles of Zener diode,
circuit. (10 hrs) varactor diode, their
70. Measure ripple voltage, ripple specifications and
frequency and ripple factor of applications. Working
rectifiers for different load and principle of a Transformer,
filter capacitors. (5 hrs) construction, Specifications
 71. Identify and test Zener diode. and types of cores used.
(2 hrs) Step-up, Step down and
72. Construct and test Zener based isolation transformers with
voltage regulator circuit. (5 hrs) applications. Losses in
73. Calculate the percentage Transformers. Phase angle,
regulation of regulated power phase relations, active and
supply. (5 hrs) reactive power, power factor
and its importance.

Computer Hardware, OS, MS office and Basic blocks of a computer,

• Install, configure, Networking Components of desktop and
16-20
interconnect given 74. Identify various indicators, cables, motherboard. Hardware and
computer system(s) connectors and ports on the software, I/O devices, and
and demonstrate & computer cabinet. (5 hrs) their working. Different types
utilize application 75. Demonstrate various parts of the of printers, HDD, DVD.
packages for different system unit and motherboard Various ports in the computer.
application. components. Windows OS MS widows:
(5 hrs) Starting windows and its
76. Identify various computer peripherals operation, file management
and connect it to the system. (5 hrs) using explorer, Display &
77. Disable certain functionality by sound properties, screen
disconnecting the concerned cables savers, font management,
SATA/ PATA. (5 hrs) installation of program, setting
and using of control panel.,

ed
78. Replace the CMOS battery and
application of accessories,
bl I extend a memory module.
pu M
various IT tools and

ish
(5 hrs)
79. Test and Replace the SMPS applications.
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(5 hrs)
80. Replace the given DVD and HDD on Concept of word processing,:
MS word – Menu bar,
be @

the system (5 hrs)

81. Dismantle and assemble the desktop standard tool bar, editing,
computer system. (10hrs) formatting, printing of
o ht

82. Boot the system from Different document etc.

options (5 hrs) Excel – Worksheet basics,
t t rig

83. Install OS in a desktop computer. (5 data entry and formulae.

hrs) Moving data in worksheet
No py

84. Install a Printer driver software and using tool bars and menu
test for print outs (5 hrs) bars, Formatting and
Co

85. Install antivirus software, scan the calculations, printing

system and explore the options in worksheet, creating multiple
the antivirus software. (5 hrs) work sheets, creating charts.
86. Install MS office software
(5 hrs) Introduction to power point
87. Create folder and files, draw pictures Basics of preparing slides,
using paint. (5 hrs) different design aspects of
88. Explore different menu/ tool/ format/ slides, animation with slides
status bars of MS word a n d etc.
practice the options. (8 hrs)
89. Explore different menu/ tool/ format/ Concept of Internet,
status bars of MS excel and practice Browsers, Websites, search
the options. (7 hrs) engines, email, chatting and
90. Prepare power point presentation on messenger service.
any three known topics with various Downloading the Data and
design, animation and visual effects. program files etc.
(5 hrs)
91. Convert the given PDF File into Word Computer Networking:-
file using suitable software. (5 hrs) Network features - Network
92. Browse search engines, create email medias Network topologies,
accounts, practice sending and protocols- TCP/IP, UDP, FTP,
 receiving of mails and models and types.
configuration of email clients. (5 Specification and
hrs) standards, types of
93. Identify different types of cables cables, UTP, STP,
and network components e.g. Coaxial cables. Network
Hub, switch, router, modem etc. components like hub,
(5 hrs) Ethernet switch, router,
94. Prepare terminations, make UTP NIC Cards, connectors,
and STP cable connectors and media and firewall.
test. (5 hrs) Difference between PC &
95. Connect network connectivity Server.
hardware and check for its
functioning. (5 hrs) 96. Configure
a wireless Wi-Fi network (5 hrs)
functioning. (5 hrs)
96. Configure a wireless Wi-Fi
network (5 hrs)
IC Regulators
97. Construct and test a +12V fixed
voltage regulator. (5 hrs)

98. Identify the different types of

Assemble simple fixed +ve and – ve regulator ICs
21 electronic power supply Regulated Power supply
and the different current ratings

ed
circuit and test for using 78XX series, 79XX
(78/79 series) (5 hrs)
functioning.
bl I series. Op-amp regulator,
pu M
99. Identify different heat sinks for

ish
723 regulator,
IC based regulators. (2 hrs)
(Transistorized & IC based).
Re NI
100. Observe the output voltage of
Voltage regulation, error
different IC 723 metal/ plastic
correction and amplification
type and IC 78540 regulators by
be @

etc.
varying the input voltage with
fixed load (8 hrs)
o ht

101. Construct and test a 1.2V – 30V

variable output regulated power
t t rig

supply using IC LM317T. (5 hrs)

No py

Project work / Industrial visit Broad areas:

Co

1. Full wave Voltage rectifier with indicator.

2. Transformer less 12 V dual power supply
22-23 3. Versatile regulated power supply
4. AC/DC voltage tester.
5. Modular rectifiers.
6. Half wave dual power supply with zener diode.

24-25 Revision

26 Examination
Electronics & Hardware Exercise 1.1.01
Electronic Mechanic - Basic workshop Practice

Visit various sections of the ITI and identify the location of various installations
Objectives: At the end of this exercise you shall be able to
• identify the ITI staff their designation and their names
• list the trades available at your ITI
• explain the location of your ITI with respect to railway/bus station and any land mark
• record the telephone numbers of ITI office, hospital, police station and fire station
• draw the layout of the ITI electronic mechanic section
• identify the location of switches and their control area.
• operate the identified switches in case of emergency.

Requirements
Tools and Instruments Materials
• Steel rule 300 mm - 1 No • Pencil HB - 1 No
• Measuring tape 20 m - 1 No • Eraser - 1 No
• Set square 300 & 600 - 1 No • Note Pad - 1 No
• Set square 450 & 450 - 1 No • A4 Sheet - 5 Nos

ed
bl I
PROCEDURE
pu M
ish
TASK 1 : Visit various section of ITI and acquaint with the staff members.
Re NI
Instructor will lead the new recruits to various 3 Identity the location of ITI with respect to railway and
be @

section of ITI. bus stations and list of bus route numbers which play
near the ITI.
o ht

1 During the visit collect information like the designation 4 Collect the telephone numbers of ITI office, nearest
of staff member, their name. hospital, nearest police station and the nearest fire
t t rig

2 Identify the sections of the ITI and list the trades in station.
which training is given.
No py

_______
Co

TASK 2 : Draw the layout of the Electronic Mechanic section

1 Draw the plan of the EM section to a suitable scale in 3 Draw the layout of the equipments, panels and furniture,
a separate sheet of paper (A4 size). etc. on the EM section plan to the same scale as in
step 1 as per the actual placement of the panels,
2 Take the length and the breadth measurements of
furniture etc.
electronic equipments, work benches, panels, doors,
windows, furniture etc.
_______

TASK 3 : Identify the location of switches and operate them during emergency.

1 Identify the main switch and mark its position in the 4 Practice switching “ON & OFF' of the controlling
layout. switches, depending upon the area of control, taking
into account the location of victims under imaginary
2 Identify each of the sub-main switches, their area of
electrocution.
control in the section and mark them on the layout.
5. Get the work checked by the instructor.
3 Identify 3 or 4 spots in various locations of the EM
section layout and identify the respective sub-main
switches.
_______

1
Electronics & Hardware Exercise 1.1.02
Electronic Mechanic - Basic workshop Practice

Identify Safety Sign for danger warning, caution & personal safety message
Objectives: At the end of this exercise you shall be able to
• Identify the safety signs for caution
• Identify the safety signs for danger and warning
• Explain the personnel safety message

Requirements
Tools/Equipments • Drawing sheet - 1 No
• Colour sketch pen - 1 Set
• Scissor - 1 No • Hard board - as reqd
Materials • Gum - as reqd
• Pencil - 1 No • Twine thread - as reqd
• Eraser - 1 No

PROCEDURE
TASK 1: Identification of safety signs for caution.

ed
1 For the safety signs given in column 1 of observation 2 Get the work checked by the instructor.

bl I
& Tabulation sheet Table identify and record the
pu M
ish
different types of signs and their meaning in columns
2 and 3.
Re NI
be @

Observation & Tabulation Sheet Table

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Sign Type Meaning

t t rig
No py
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2
Sign Type Meaning

ed
bl I
pu M
ish
Re NI
be @
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t t rig
No py
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Electronics & Hardware : Electronic Mechanic - Exercise 1.1.02 3

TASK 2: Identify the safety signs for danger & Warning. Danger

Sign Type Meaning

ed
bl I
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ish
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be @
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No py
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4 Electronics & Hardware : Electronic Mechanic - Exercise 1.1.02

Warning

Sign Type Meaning

ed
bl I
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ish
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be @
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t t rig
No py
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_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.1.02 5

TASK 3 : Explain the personal safety messages

Electrical Safety Practices at Work Insulated Tools

Safe work practices are used to prevent electrical shock Insulated tools must be used when working on or near
or similar injuries by keeping workers away from ener- exposed energized live conductors.Not all tools with a
gized equipment or circuits and by training qualified work- plastic coating or plastic handles provide protection from
ers on the correct procedures when working on ener- electrical shock. It is important to inspect your tools be-
gized equipment or circuits. Prior to using or performing fore performing electrical work - not only to verify if the
maintenance on electrical equipment, the employee tools are rated for the job, but also to check for damage,
should first determine if it is safe by checking the follow- wear and if they no longer provide adequate protection
ing. from electrical shock. Damaged or worn tools should be
removed from service immediately.
• Verify that electrical equipment is not located in a
hazardous environment, such as a damp/wet location DO’S
or where it is exposed to high temperatures and • Read and follow electrical instruction manuals prior
flammable gases and vapours. to using .
• Make sure overcurrent and safety devices, such as • Use safety signs, barricades and tags to identify
fuses, circuit breakers and ground fault circuit and protect electrical equipment.
interrupters (GFCI), have not been tampered with
and are working correctly. • Only use extension cords as a temporary solution.

• Inspect the power cord and plug to ensure there are • Use waterproof cords in an outdoor application
no defects, such as cuts in the insulation exposing • Contact a certified electrician when electrical repair
bare wiring. is needed

ed
• Identify if the equipment has an emergency shut off DONT’S

bl I
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switch and where it is located prior to use.

ish
• Overload outlets by using splitters.
• Make sure there is sufficient space around the
Re NI
electrical equipment or circuit to allow for operation • Touch electrical equipment, including power cords
and maintenance with wet or damp hands.
be @

• Remove all personal metal jewellery prior to using or • Allow dirt, grease or dust to accumulate on electrical
working on electrical equipment or circuits. equipment.
o ht

• If de-energizing the electical equipment or circuit • Use temporary wiring in place of permanent wiring.
will increase the potential for an electrical hazard or
t t rig

• Use cords or equipment that are not properly

is necessary for testing and trouble shooting, the grounded.
appropriate tools and personal protective equipment
No py

(PPE) must be used and worn.

Co

_______

6 Electronics & Hardware : Electronic Mechanic - Exercise 1.1.02

Electronics & Hardware Exercise 1.1.03
Electronic Mechanic - Basic workshop Practice

Use of Personal Protective Equipment (PPE)

Objectives : At the end of this exercise you shall be able to
• state use of different PPES

Requirements
Tools and Instruments • Drawing sheet - 1 No
• Colour sketch Pen - as reqd
• Scissor - 1 No
• Gum - as reqd
Materials: • Twine thread - as reqd
• Pencil - 1 No
• Eraser - 1 No

PROCEDURE
TASK 1 : Use of different PPEs

1 For the PPEs given in column 1 sheet, write the use of

ed
PPEs.

bl I
2 Get the work checked by the Instructor.

pu M
ish
PPES USE
Re NI
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t t rig
No py
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7
 PPES USE

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

8 Electronics & Hardware : Electronic Mechanic - Exercise 1.1.03

Electronics & Hardware Exercise 1.1.04
Electronic Mechanic - Basic workshop Practice

Practice elementary First Aid

Objectives: At the end of this exercise you shall be able to
• rescue a person from live wire
• apply respiratory resuscitation.

Requirements
Equipments/Machines Materials

• A wall mounted/pedestal bus-bar chamber • Workshop coats, sacks, long handled wooden
controlled by an isolator - dummy - not con- brush, length of timber, rubber mat, hot water bag.
nected to mains - an Electrical machine con-
nected through an isolator - (dummy - not
connected to mains).

PROCEDURE

TASK 1 : Disconnecting a person (mock victim) from a live supply (simulated)

ed
2 Remove the victim safely from the `live` equipment by

bl I
disconnecting the supply or using one of the items of
pu M
ish
insulating material.
Re NI
Do not run to switch off the supply that is far
away.
be @

Do not touch the victim with bare hands until

the circuit is made dead or the victim is moved
away from the equipment.
o ht

Push or pull the victim from the point of contact

of the live equipment, without causing serious
t t rig

injury to the victim.

No py

3 Move the victim physically to a nearby place.

4 Check for the victim's natural breathing and cons
Co

1 Observe the person (mock victim) receiving an elec- ciousness.

tric shock. Interpret the situation quickly. 5 Take steps to apply respiratory resuscitation if the
victim is unconscious and not breathing.

_______

TASK 2 : Artificial respiratory resuscitation

1 If breathing has stopped, apply immediate artificial 5 Look for visible injury in the body and decide on the
respiration. suitable method of artificial respiration.
2 Loosen the tight clothing of the victim. If not possible 6 Have you observed ? (In this case you are told by the
to loosen quickly, do not spend too much time in this instructor.)
activity.
7 In the case of injury/burns to chest and/or belly follow
3 Remove obstructions from the mouth, if any. the mouth to mouth method.
4 Send word for professional assistance. (If no other 8 In case the mouth is closed tightly, use Schafer's or
person is available, you stay with the victim and render Holgen–Nelson method.
help as best as you can.)
9 In the case of burn and injury in the back, follow
Nelson's method.

9
10 Arrange the victim in the correct position for giving
All action should be taken immediately.
artificial respiration. Follow the steps explained, given
Delay even by a few seconds may be dangerous.
under skill information for each method of artificial
Exercise extreme care to prevent injury to
respiration, until the victim breathes naturally or pro-
internal organs.
fessional help arrives.
11 Place the mock victim in the recovery position.
12 Cover the victim with coat, sacks or improvise your
own method. It helps to keep the victim's body warm.

_______

Skill Sequence

Artificial respiration - Nelson's arm - lift back - pressure method

Objectives : This shall help you to
• resuscitation of a victim by the Holgen–Nelson method.

Nelson's arm-lift back-pressure method 2 Gently rock forward keeping the arms straight until
they are nearly vertical, and thus steadily pressing
Caution
the victim's back as in Fig 2 to force the air out of the
– Remove the victim from contact with the live equip- victim's lungs.
ment. (Ref. related theory - Artificial respiration)

ed
bl I
– Tight clothing which may interfere with the victim's

pu M
ish
breathing must be loosened.
Re NI
– Remove any foreign materials or false teeth from his
mouth, and keep the mouth open.
be @

– Do not delay artificial respiration for loosening clothes

or even if the mouth is closed tightly.
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Nelson's arm-lift back pressure method must

not be used in case there are injuries to the
t t rig

chest and belly.

No py

1 Place the victim prone (that is, face down) with his
arms folded with the palms one over the other and the
Co

head resting on his cheek over the palms. Kneel on

one or both knees near the victim's hand. Place your
3 Synchronizing the above movement rock back-
hands on the victim's back beyond the line of the
wards, slide your hands downwards along the victim's
armpits, with your fingers spread outwards and down-
arms and grasp his upper arm just above the elbows
wards, thumbs just touching each other as in Fig 1.
as shown in Fig 3 Continue to rock backwards.

10 Electronics & Hardware : Electronic Mechanic - Exercise 1.1.04

4 As you rock back, gently raise and pull the victim's Other steps
arms towards you as in Fig 4 until you feel tension
1 Send for a doctor immediately.
in his shoulders. To complete the cycle, lower the
victim’s arms and move your hands up to the intial 2 Continue artificial respiration till the victim begins to
postion 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 conscious.

Artificial respiration - Schafer's method

ed
bl I
Objectives: This shall help you to
pu M
ish
• resuscitation of a victim by the Schafer's method.
Re NI
Schafer's method
– Do not use this method in case of injuries to victim on
be @

the chest and belly.

– Make the equipment dead by opening the switch and
o ht

release the victim.

t t rig

– If the victim is aloft, measures must be taken to

prevent him from falling or to make him fall safe.
No py

– Do not touch the victim with bare hands until you are
sure that he is free from electrical contact.
Co

Caution
Tight clothing which may interfere with the victim's
breathing must be loosened; all foreign matter, such
as false teeth, tobacco, pan, etc. should be removed
from his mouth. Delay by even a few seconds may be
dangerous.
Avoid violent operations to prevent injury to the
internal parts.
1 Lay the victim on his belly, one arm extended
directly forward, the other arm bent at the elbow and
with the face turned sideward and resting on the hand 4 Now swing backward immediately removing all
or fore-arm as shown in Fig 1. pressure from the victim's body as shown in Fig 3,
and thereby allowing the lungs to fill with air.
2 Kneel astride the victim, so that his thighs are
between your knees and with your fingers and 5 After two seconds, swing forward again and repeat
thumbs positioned as in Fig 1. the cycle twelve to fifteen times a minute.
3 With the arms held straight, swing forward slowly so
that the weight of your body is gradually brought to
bear upon the lower ribs of the victim to force the air
out of the victim's lungs as shown in Fig 2.

Electronics & Hardware : Electronic Mechanic - Exercise 1.1.04 11

 Other steps
1 Send for a doctor immediately.
2 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.
3 Continue artificial respiration till the victim begins to
breathe naturally. Beware it may take hours even.
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 con-
scious.

Artificial respiration - mouth to mouth method

Objectives: This shall help you to
• perform resuscitation of a victim by mouth to mouth method

Mouth-to-mouth method of artificial respiration

ed
– Free the victim from the live equipment before com-

bl I
mencing artificial respiration.
pu M
ish
Caution
Re NI
– Loosen tight clothing which may interfere with the
victim's breathing.
be @

– Make sure that the airways (nose and mouth) are

clear. Remove loose dentures or other obstructions
o ht

from the mouth.

– Do not delay artificial respiration for loosening the
t t rig

clothes. Delay even by a few seconds may be

dangerous.
No py

1 Lay the victim flat on his back and place a roll of

clothing under his shoulders to ensure that his head
Co

is thrown well back. (Fig 1)

3 Take a deep breath and place your mouth over the

victim's mouth as shown in Fig 4 making airtight
contact. Pinch the victim's nose shut with the thumb
and forefinger. If you dislike direct contact, place a
Tilt the victim's head back so that the chin points porous cloth between your mouth and the victim's.
straight upward. (Fig 2) For an infant, place your mouth over its mouth and
nose. (Fig 4).
2 Grasp the victim's jaw as shown in Fig 3, and raise
it upward until the lower teeth are higher than the 4 Blow into the victim's mouth (gently in the case of
upper teeth; or place fingers on both sides of the jaw an infant) until his chest rises. Remove your mouth
near the ear lobes and pull upward. Maintain the and release the hold on the nose, to let him exhale,
jaw position throughout the artificial respiration to turning your head to hear the out-rush of air. The first
prevent the tongue from blocking the air passage. 8 to 10 breaths should be as rapid as the victim
responds, thereafter the rate should be slow down to
about 12 times a minute (20 times for an infant).

12 Electronics & Hardware : Electronic Mechanic - Exercise 1.1.04

 Quick action is essential
• Lay the victim on his back on a firm surface.
• Kneel alongside, facing the chest and locate the
lower part of the breastbone. (Fig 7).

If air cannot be blown in, check the position of

the victim's head and jaw and recheck the
mouth for obstructions, then try again more
forcefully. If the chest still does not rise, turn
the victim's face down and strike his back
sharply to dislodge obstructions.
Sometimes air enters the victim's stomach as
evidenced by a swelling stomach. Expel the • Place the palm of one hand on the centre of the lower
air by gently pressing the stomach during the part of the breastbone, keeping your fingers off the
exhalation period. ribs. Cover the palm with your other hand and lock
your fingers together. (Fig 8)
Mouth to nose method: If the victim's mouth will not
open, or has a blockage you cannot clear, use the
fingers of one hand to keep the victim's lips firmly

ed
shut, seal your lips around the victim's nostrils

bl I
pu M
and breathe into him. Check to see if the victim's

ish
chest is rising and falling. (Fig 5)
Re NI
be @
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• Keeping your arms straight, press sharply down on

the lower part of the breastbone; then release the
t t rig

pressure. (Fig 9)
No py
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Cardiac arrest: In cases where the heart has stopped

beating, you must act immediately.
You should check if:
• The carotid pulse in the neck can be felt (Fig 6).
• The casualty is blue around the lips.
• The pupils of his eyes are widely dilated.

• Repeat this 15 times at a rate of atleast once per

second.
• Check the carotid pulse.
• Move back to the victim's mouth to give two breaths
(mouth-to-mouth resuscitation). (Fig 4)
• Continue with another 15 compressions of the heart,
followed by a further two breaths of mouth-to-mouth
resuscitation, and so on, checking for the pulse at
frequent intervals.

Electronics & Hardware : Electronic Mechanic - Exercise 1.1.04 13

• As soon as the heartbeat returns, stop the Other aids
compressions immediately but continue with mouth-
to-mouth resuscitation until natural breathing is fully 1 Send for a doctor immediately.
restored. 2 Keep the victim warm with a blanket, wrapped up hot
• Place the victim in the recovery position. Keep him water bottles or warm bricks; stimulate circulation by
warm and get medical help quickly. (Fig 10) stroking the insides of the arms and legs towards the
heart.
3 Continue artificial respiration till the viticm begins to
breathe naturally. It may take hours.
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 con-
scious.

_______

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
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14 Electronics & Hardware : Electronic Mechanic - Exercise 1.1.04

Electronics & Hardware Exercise 1.1.05
Electronic Mechanic - Basic workshop Practice

Preventive measure for electrical accidents & steps to be taken in such

accidents
Objectives : At the end of this exercise you shall be able to
• easy ways to prevent electrical accidents
• steps to be taken in electrical accidents.

PROCEDURE
TASK 1 : Easy ways to prevent electrical accidents

1 Only licensed electricians install, repair and 6 Check insulated tools for damage before each use.
dismantle jobsite wiring.
7 Never modify electrical plugs.
2 Always plug into a GFCI. (Ground Fault Circuit
8 Keep extension cords in a safe place where they
Interrupter protection)
won’t be stepped on or driven over.
3 Check each extension cord before use.
9 Ensure that all electrical components stay dry.
4 Do a Thorough check for electrical wiring before
10 Use the right extension cord for the job.
cutting through any wall, floor or ceiling.
11 Get the work checked by the Instructor.

ed
5 Inspect power tools on a regular basis.

bl I
pu M
ish
_______
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TASK 2 : Step to be taken in electrical accidents.
be @

1 Use only equipment that is properly grounded or 9 Do not ignore warning signs. If an item feels hot,
double-insulated. makes an unusual noise (buzz or hum), smokes or
sparks take it out of service immediately and tag it “Do
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2 Do not overload outlets

Not Use”
3 Do not plug multi-outlet bars to other multi-outlet
t t rig

10 Inspect cords and equipment regularly, and report any

bars
defects immediately.
No py

4 Only use equipment that has been approved by a

11 Cover or guard any exposed electrical components or
national testing laboratory.
wires and make sure employees are aware of any
Co

5 Minimize the use of extension cords. Do not plug hazards.

two extension cords together.
12 Unplug cords from the outlet by gripping the plug. Do
6 Do not cover power cords or extension cords with not just pull the cord from a distance.
rugs or mats, as this can cause issues with the
13 Do not use electrical equipment or appliances near
wires or create potential tripping hazards.
water or wet surfaces.
7 Do not run electrical cords through pedestrian nar
14 Never use electrical equipment when your hands or
row gap as this creates tripping hazards.
the equipment is wet.
8 Unplug or disconnect machines before servicing or
15 Get the work checked by the instructor.
repairing, and check to make sure the machine is
actually disconnected and turned off prior to service.

_______

15
Electronics & Hardware Exercise 1.1.06
Electronic Mechanic - Basic workshop Practice

Use of Fire Extinguisher

Objectives : At the end of this exercise you shall be able to
• identify the types of fires
• identify the different types of fire extinguisher
• select the proper types of fire extinguisher
• use of fire extinguisher.

Requirement
Tools and Instruments Materials/ components
• Fire Extinguisher - 1 No each • Scrap material like wood /
(different type Fire Extinguishers) wire/oil/ cotton cloth - as reqd

PROCEDURE
TASK 1 : Identify the types of Fires.

ed
1 Instruct someone to inform the fire department record 3 Get the right type of Fire Extinguisher.

bl I
ing location.
4 Make sure your fire extinguisher is upto date.
pu M
ish
2 First you ascertain what kind of fire it is.
5 Get the work checked by the instructor.
Re NI
be @

_______
o ht

TASK 2 : Identify the different types of Fire Extinguishers

t t rig

1 Identify and record the type of Fire Extinguishers 2 As instructed by your instructor take part in the
available in your institute also record the type and general type of fire - fighting and electrical fire.
No py

class of fires in which these Fire Extinguishers can

3 Get the work checked by the instructor.
use in Table 1.
Co

Table 1

S No. Type of Fire Extinguisher Fire Type

_______

16
TASK 3 : Use of Fire Extinguisher

1 Stand with your back to an exit as shown in Fig 1 5 Aim the hose at the base of the fire as shown in Fig 4

2 Move to the proper distance. Many fire extinguishers 6 Squeeze the lever as shown in Fig 5
have a range of between 8 and 12 feet (2.4 to 3.7m).
before discharging the extinguisher, move towards or
away from the fire so you’re standing 6 to 8 feet (1.8
to 2.4m) away as shown in Fig 2.

ed
bl I
pu M
ish
Re NI
be @

7 Sweep the hose side to side as shown in Fig 6

o ht
t t rig

3 The PASS method is used for Fire Extinguisher

No py

P: Pull the Safety PIN from the handle.

Co

A: AIM at the base of the fire

S: SQUEEZE the trigger.
S: SWEEP from side to side
4 Pull the pin as shown Fig 3

8 Back away and repeat if the flames flare up as shown

in Fig 7

Electronics & Hardware : Electronic Mechanic - Exercise 1.1.06 17

9 Leave immediately if you’re unable to extinguish the 10 Replace or recharge your fire extinguisher as soon
fire as shown in Fig.8 as possible.
11 Get the work checked by the Instructor.

_______

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

18 Electronics & Hardware : Electronic Mechanic - Exercise 1.1.06

Electronics & Hardware Exercise 1.1.07
Electronic Mechanic - Basic workshop Practice

Identify stet different hand tools

Objectives : At the end of this exercise you shall be able to
• identify the tools when specification is given
• identify the tools for specific uses.

Requirements
Tools/Instruments Material/Components
• Combination pliers 200 mm - 1 No • Neon tester - 1 No
• Long round nose pliers 200 mm - 1 No • Electrician knife - 1 No
• Screwdriver 150mm - 1 No • Centre punch - 1 No
Equipment/Machines
• Portable electric drilling machine - 1 No

The instructor shall arrange for tools and the

required materials from scrap for practising
the functioning of tools.

ed
bl I
PROCEDURE
pu M
ish
TASK 1 : Identify the tools when specification is given
Re NI
1 Draw a neat sketch against each item given below.
Assumption: A set of trainee’s tool kit and
be @

specified tools as given in this exercise are to

In case of change in specification, rewrite the
be displayed on the workbench. Trainees are
correct specification of the items given to you.
o ht

required to identify the tools from the specifi-

cation given below and draw the sketch of the
t t rig

tools in the allotted column.

No py

Specification Sketch of tools

Co

i Combination pliers 200 mm

ii Long round nose pliers 200 mm.

iii Screwdriver 0.8 x 6 x 150 mm

19
TASK 2 : Identifying tools for specific uses iii Pliers-diagonal cutting
It is used for shearing off wires in confined spaces and
From the list given select the correct name of each of the
cutting off wires close to the surface level.(Fig 5)
pliers given
1 Practice the use of each tool for different operations as
given below.
i Combination pliers (Fig 1)
Pipe grip is serrated for gripping cylindrical objects.

ii Pliers-flat nose
Two joint cutters are provided for cutting or shearing off iv Pliers-round nose
wires. (Fig 2)

ed
It is used to shape loops in wires and to form curves in light

bl I
metal strips.(Fig 6)

pu M
ish
Re NI
be @
o ht
t t rig

Side cutting edges are provided for cutting of soft wires.

(Fig 3)
No py
Co

v Screwdriver
It is used for slot head screws.
Use screwdrivers with tips correctly fitting into the screw
slot. (Fig 7)

It is used for bending and folding narrow strips of thin

sheet metal. (Fig 4)

20 Electronics & Hardware : Electronic Mechanic - Exercise 1.1.07

vi Screwdriver - Star ix Centre punch
It is used for star-headed screws.(Fig 8) It is used for making punch marks on met (Fig 11)

Fig 11

x Portable electric drilling machine

vii Neon tester
It is used for drilling holes in wood or metals
It is used for testing live terminals.(Fig 9)

Fig 12

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py

viii Electrician's knife

It is used for skinning the insulation.(Fig 10)
Co

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.1.07 21

Electronics & Hardware Exercise 1.1.08
Electronic Mechanic - Basic workshop Practice

Selection of proper tools for operation and precautions in operation

Objectives: At the end of this exercise you shall be able to
• select proper tools for operation
• precaution while using hand tools.

PROCEDURE
TASK 1: Select proper tools for operation

1 First, know and understand in detail, the scope of 4 Use the tool for the purpose for which it was designed
work to be accomplished.
5 Provide and use properly the right personal protective
2 Plan for the scope taking into account the sequence equipment .
of tasks.
6 Get the work checked by the Instructor.
3 Select best tool for each task and follow the
manufacturer’s guidance and instructions for that
specific tool.
_______

ed
bl I
TASK 2 : Precaution while using hand tools
pu M
ish
Re NI
1 Use the right tool for the job as shown in Fig 1 6 Keep close track of tools when working at heights. A
falling tool can kill a co-worker.
7 Pass a tool to another person by the handle; never
be @

toss it to them.
8 Use the right personal protective equipment (PPE) for
o ht

the job. Follow manufacturer’s instructions for select-

t t rig

ing and using safety eyewear, steel toed shoes,

gloves, hard hats etc.
No py

9 Never carry sharp or pointed tools such as a screw

driver in your pocket.
Co

10 Select ergonomic tools for your work task when move-

ments are repetitive and forceful.
2 Don’t use broken or damaged tools, dull cutting tools,
or screwdrivers with worn tips. 11 Be on the lookout for signs of repetitive stress.
Early detection might prevent a serious injury.
3 Cut in a direction away from your body.
12 Always keep your tools in top condition. A dull blade
4 Make sure your grip and footing are secure when us- or blunt point can lead to injury.
ing large tools.
13 Store tools properly when you stop work.
5 Carry tools securely in a tool belt or box. Don’t carry
tools up ladders. Use a hoist or rope. 14 Get the work checked by the Instructor.

_______

22
Electronics & Hardware Exercise 1.1.09
Electronic Mechanic - Basic workshop Practice

Care and maintenance of trade tools

Objectives: At the end of this exercise you shall be able to
• care and maintenance of trade tools.

Requirements
Materials
• Cotton Cloth - as reqd
• Lubricating oil - as reqd

PROCEDURE
TASK 1 : Care and maintenance of trade tools

1 Wipe or clean after every use with a clean and soft 8 Never use screwdrivers as wood chisel nor cold
to remove dirt. chisel.
2 Keep all tools in a tool room or tool rack. 9 If necessary, never file the soldering tip of soldering
copper.
3 Tools should be applied with appropriate oil to

ed
prevent them from rusting. 10 Do not overheat the electric soldering iron.

bl I
pu M
ish
4 Drill tools should be sharpened properly if they are 11 Never use dull tools, it will cause harm to your work
dull. or yourself.
Re NI
5 Tooth cutting tools should be sharpened as often as 12 Always issue or lend tools with receipt.
necessary.
be @

13 Tools borrowed should be returned in good condition,

6 Never drop tools especially precision instruments otherwise it should be replaced with a new and of the
or testing tools. same kind.
o ht

7 Except hammers, never use tools as hammers. 14 Get the work checked by the Instructor.
t t rig
No py

_______
Co

23
Electronics & Hardware Exercise 1.1.10
Electronic Mechanic - Basic workshop Practice

Practice safety precautions while working in fitting jobs

Objectives : At the end of this exercise you shall be able to
• Practice safety precautions while working in fitting job
• Practice safety precautions while measuring with OS caliper
• Practice safety precaution while hacksawing.
• Practice safety precaution while chipping & grinding
• Practice safety precaution while drilling and tapping.

Requirements
Materials
• Cotton cloth - as reqd

PROCEDURE
TASK 1 : Practice safety precautions while working in fitting jobs.

Filing Flat Surface

ed
1 Hold the job in the bench vice with a projection of 5 to

bl I
10mm from the top of the vice jaw as shown in Fig 1

pu M
ish
Re NI
be @
o ht
t t rig

Practice safety precaution while measuring with out-

No py

side calipers
1 Open the jaws of calipers untill they pass clearly
Co

over the diameter to be measured as shown in Fig 4

2 Check whether the handle of the file tightly hold the
handle of file and push the file forward using your
right hand palm as shown in Fig 2

Practice safety precaution while hacksaw cutting

1 Insufficient blade tension cut will not be straight
2 Over tension - blade will break
Start filing by pushing file uniformly during the forward
Practice safety precaution while chipping using flat
stroke and release the pressure during the return stroke
chisel.
as shown in Fig 3
1 Install the chipping screen while chipping as shown in
Fig 5

24
Practice safety precaution while grinding
1 Protect your eyes with goggles or lower the protect-
ing shield near the tool rest shown in Fig 6

Practice safety precaution while Tapping

1 Exert steady downward pressure and turn the tap
wrench slowly in the clockwise direction to start
the thread.
2 Hold the tap wrench close to the centre as shown in

ed
Fig 8

bl I
pu M
ish
Re NI
be @
o ht

Practice safety precaution while drilling

t t rig

1 Fix securely the drill deep into the drill chuck as shown
in Fig 7
No py
Co

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.1.10 25

Electronics & Hardware Exercise 1.1.11
Electronic Mechanic - Basic workshop Practice

Workshop Practice on filing and hacksawing

Objectives: At the end of this exercise you shall be able to
• file one face flat and check by straight edge and light gap (R)
• file angle to 90o within try square accuracy(R)
• mark straight lines(R)
• mark parallel lines using a surface gauge
• mark parallel lines using a try square
• file and finish surfaces flat and parallel within ± 0.5mm (R)
• file and finish radius
• saw M.S.flat along a straight line.

Requirements
Tools/Instruments Equipment/Machines
• File, flat bastard, double cut 300mm - 1 No • Bench vice - 1 No
• File, flat, second cut, double cut • Surface plate - 1 No
300mm - 1 No • Angle plate - 1 No
• Try square - engineer's rule 150mm - 1 No
Materials

ed
• Jenny caliper 150mm - 1 No
• Engineer ball peen hammer 200gm - 1 No

bl I
• 60 ISF 8 (Length - 350mm.) - 2 Nos
• Centre punch
pu M - 1 No

ish
• ISA 5555 (Thickness 8mm
• Dot punch - 1 No
length 150mm ) - 1 No
Re NI
• Steel rule 300mm - 1 No
• Hacksaw blade, 280mm, 300mm - 1 No
• Surface gauge - 1 No
be @

• Radius gauge - 1 Set

• File card - 1 No
o ht

• Vice clamp - 1 Pair

• Divider - 1 No
t t rig

• Straight edge - 1 No
No py

PROCEDURE
TASK 1 : Practice on Filing
Co

1 Check the length and size of the given M.S angle iron
as per the sketch using a steel rule.
2 Fix the angle iron at right angle and one side (surface
A) at least 15 mm above the jaws of the bench vice.
3 File the reference side (surface A indicated in Fig 1)
with the bastard file.
4 Test the flatness with the blade of the try square.
5 File the adjacent surface ‘B’ with a bastard file.
6 Test the flatness and also check the right angle with
the try square.
7 File the side C at right angle to surfaces A,B.
8 Apply marking media (lump chalk) evenly on the
surfaces A and B.
9 Place the surface B on the levelling plate and scribe a
line parallel to B on surface A (at a distance of 53mm
as shown in Fig 1); likewise mark on surface A a line
parallel to B at a distance of 53mm.

26
10 Place the surface C on the levelling plate and scribe a 14 Use an outside caliper for checking the finished sizes.
line parallel to C on the surfaces A & B at a distance of
15 Deburr all sharp edges.
146 mm from the surface C
11 Punch all the scribed lines. Do not touch the surface of the job while filing.
Use a vice clamp for protecting the finished
12 File the sides D,E and F with a bastard file.
surface.
13 Finish the job with a second cut file, file within ± 0.5mm Do not overtighten the vice.
and check the right angles with reference to surfaces Do not allow any pining of the file handle.
A & B. For removing pining of the file use a file card.

_______

TASK 2 : Practice on Hacksawing

1 Check the raw material size as per sketch using the 22 File and finish the job with a second cut file within
a tolerance of ± 0.5mm (use outside calipers for
steel rule.
checking).
2 Fix the job securely in the bench vice.
3 File the reference face A with a bastard file.
4 Check the flatness with the straight edge.

ed
5 File adjacent edge or datum edge B with a bastard file.

bl I
6 Check the right angle with a try square.
pu M
ish
7 File adjacent edge or datum edge C with a bastard
Re NI
file.
8 Check the right angles to the datum edge B and
be @

reference surface A.
9 Apply chalk evenly on the surface A.
o ht

10 Place the job on the levelling plate and scribe the

t t rig

lines by the surface gauge parallel to the datum edge

B (size 58mm) and on datum edge C (size 350mm).
No py

11 Scribe the saw cut parallel lines a, b, c & d as per

sketch.
Co

12 Scribe two arcs of radius 10mm with the divider

at the datum edge C as in the figure.
13 Punch all the scribed lines and also the arcs by a
dot punch.
14 File the edges D and E with a bastard file.
15 Check for the right angle between edges D and E and
also with the surface A.
16 Check the finished size length 350mm and breadth
58 mm with an outside caliper.
17 Saw the depth a, b c and finally saw to part at d.
18 File and finish the saw-cut surface of part 1 for a
length of 300 mm.
19 Saw the corners for removing the unwanted metal for
filing radius.
20 File and finish two corners by radius filing on part 1.
21 Check the radius with a radius gauge.

_______
Electronics & Hardware : Electronic Mechanic - Exercise 1.1.11 27
Electronics & Hardware Exercise 1.1.12
Electronic Mechanic - Basic workshop Practice

Practice simple sheet metal works, fitting and drilling

Objectives: At the end of this exercise you shall be able to :
• calculate the distance of the lap, the distance between centre of first rivet and edges and the distance of pitch
as per BIS standard
• layout the spacing for rivet holes to make a single riveted lap joint.
• drill correct sized hole on sheet metal by operating power operated portable drilling machine properly.

Requirements
Tools and Instruments Equipment/Machines
• Steel rule 300 mm - 1 No • Hand drilling machine - 1 No
• Scriber 200 mm - 1 No
Materials
• Centre Punch 150 mm - 1 No
• Rivet set for14 Timans rivet - 1 No • Sheet metal 18ST 55x0.5x105 - 2 Nos
• Hammer 250 gm - 1 No • No 14 Timan riverts - 10 Nos

PROCEDURE

ed
TASK 1 : Practice single sheet metal works for fitting

bl I
pu M
ish
1 Ensure the edges of the workpieces to be joined are
Re NI
free of burr and straight.
2 Calculate the distance of the lap. Distance of the lap =
be @

4 x Dia of the rivet (D) Diameter of the rivet = 2.5 or 3t

from the known thickness.
o ht

3 Calculate the dia of the rivet, and calculate the distance

of the lap.
t t rig

4 Mark the line of distance of the lap parallel to the

edge, on both workpieces using a scriber and a
No py

steel rule. (Fig 1)

Co

7 Calculate the distance of the first rivets from the side

edge. Distance of the first rivet from the edge = 2 x dia
of rivet (D)
8 Mark the distance of the first rivets from the side edges
on the rivet line, on both the workpieces using a
divider.
9 Calculate the distance between two rivets i.e. pitch.
Pitch = 3 x the dia of rivet (D)
5 Calculate distance of the rivet line from the edge of the 10 Mark the pitch of the rivets on the rivet lines, on
sheet.Distance of the rivet line from the edge = 2 x both workpieces (Fig 2) using a divider.
the diameter of the rivet (D) 11 Punch the centre points of the rivets using a
6 Mark the rivet lines parallel to the edge, on both centre punch and a setting hammer.
workpieces (Fig 2).

_______

28
TASK 2 : Practice simple sheet metal works for drilling

1 Punch the marked centre points of the holes to be

drilled lightly using a centre punch and a setting
hammer.
2 Insert a straight shank, drill bit in the drill chuck of the
portable drilling machine and tight with the chuck
key. (Fig 1)

5 Switch ‘ON’ the trigger switch with second finger.

6 Apply pressure on the drill chuck till you get the hole.

Before inserting the drill in the drill chuck of the While drilling by electric operated portable drill-
ing machine on a sheet metal, light pressure

ed
power operated portable drilling machine, be
sure that the switch is off and earthing is provided. should be applied otherwise, the drill will stall

bl I
or pick up the workpiece.(Fig 3)
pu M
ish
3 Place the workpiece on a suitable wooden support
Re NI
andclamp with the help of a ‘C’ clamp.(Fig 2) 7 Switch off the drilling machine after the drilling is completed.
Deburr the holes by larger sized drill bit by rotating it on
4 Hold the butt of the portable drilling machine in onehand the drilled hole by hand.
be @

and grasp the gun with fore finger and thumb of the
other hand, such that the drill is perpendicular to the
surface of the metal to be drilled (Fig 2).
o ht
t t rig
No py
Co

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.1.12 29

Electronics & Hardware Exercise 1.1.13
Electronic Mechanic - Basic workshop Practice

Making an open box from metal sheet

Objectives: At the end of this exercise you shall be able to
• draw a development plan for a given open rectangular box in a single sheet
• drill hole using hand drilling machine of small diameter
• shear straight edge using straight snip (R)
• make holes in sheet metal using cold punch (R)
• make holes in sheet metal using hollow punch.

Requirements
Tools/Instruments Equipment/Machines
• Steel rule 30 cm - 1 No • Hand drilling machine - 6mm
• Scriber 200 mm - 1 No
Materials
• Divider 150 mm - 1 No
• Snips 250 mm - 1 No • Sheet iron ISST - 52 x 0.5 x 150mm.
• Hammer 200 g - 1 No
• Hatchet stake - as avl
• Mallet wood - 1 No

ed
• Hollow punches set 3 to 25mm - 1 set

bl I
pu M
ish
PROCEDURE
Re NI
1 Check the dimension of the given metal sheet.
2 Mark all the dimensions as per drawing (Fig 1) for
be @

cutting, bending and punching holes.

3 Drill 2 mm diameter holes using hand drilling machine
o ht

on all corners of box.

t t rig

4 Shear over a length of 8.5mm for bending indicated by

No. 1 in the drawing. (Fig 1)
No py

5 Bend to 90o at all the four corners. Bending width of

8mm is indicated by No. 2 in Fig 1.
Co

6 Bend the sides B & D to 90o using suitable stack.

(Fig 2)

Electronics & Hardware : Electronic Mechanic - Exercise 1.1.13

30
 10 Make two marks on both centre lines of holes at a
Ensure the overlap parts are well within the
distance equal to the radius to locate punches.
bending line of side A and side C.
11 Place sheet on end of wood or lead cake.
7 Bend the sides A & C to 90 o. Use suitable stack.
12 Punch holes with correct size punches locating exactly
(Fig 3)
their positions.
8 Repeat steps 1 to 8 and prepare another open box.
13 Flatten the surface by gently hammering with the soft
9 Mark the centre lines as per the dimensions given in mallet.
(Fig 3), in one of the open end box made.

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.1.13 31

Electronics & Hardware Exercise 1.2.14
Electronic Mechanic - Basic Electricity

Identify the phase and neutral and earth on power socket use testers to monitor
AC power
Objectives : At the end of this exercise you shall be able to
• test and identify phase, neutral and ground points of a single phase AC mains 3-pin socket using,
1 test lamp
2 neon tester
3 AC voltmeter.

Requirements
Tools/Instruments/Equipments Materials/Components
• Trainees kit - as reqd • PVC wire,
• Neon tester, 500V - 1 No Red colour, (5/20 gauge) -1m
• Test lamp - 1 No Black colour, (5/20 gauge) -1m
• AC Voltmeter 0-500V MI - 1 No • Incandescent bulb,25 watts
• Ohmmeter - 1 No (per batch) - 1 No
• Lamp holder - 1 No
• Lamp grill - 1 No

ed
bl I
pu M
ish
PROCEDURE
Re NI
TASK 1 : Test phase and neutral points using test lamp
be @

1 Make a Test lamp setup as shown in Fig 1. 4 Connect the test lamp across the 3-pin socket outlet
points(A&B) as shown in Fig 3 and check the presence
of mains supply.
o ht

If supply does not exist (lamp does not glow),

t t rig

consult your instructor before carrying out

further steps.
No py
Co

2 Test the continuity at the free ends using an ohmmeter

to confirm correct wiring and connections of the test
lamp. The lamp grill is used to prevent damage to the
bulb.
3 On a 3-pin 230V, AC mains socket to identify phase,
neutral points, mark the two points as A and B using a
sketch pen as shown in Fig 2. 5 Touch the one end of the test lamp to Earth point and
the other end of the test lamp to the outlet terminal
marked ‘B’ as shown in Fig 4a. Check the test lamp
glows.
If lamp glows, the outlet point B is Phase or Live(L) -
mark outlet B as ‘L’ using sketch pen.
If lamp does not glow, the outlet point B is Neutral(N)
- mark outlet B as ‘N’.
6 Repeat step 4 with the test lamp across Earth and
outlet A on the socket as shown in Fig 4b.

32
 7 From the markings on the socket,check
- If the points ‘A’ and ‘B’ have the same marking(L
or N). If yes,then,there is some defect with the
mains supply or socket wiring. Consult your
instructor.
- If the points ‘A’ and ‘B’ have different markings,
and check if the L and N are at the correct
positions of the mains outlet socket.
8 Connect the test-lamp across the identified phase and
earth point. Check if the test lamp OFF or continues to
glow. From the observation made conclude whether
the ON/OFF switch is connected properly or not.

_______

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.14 33

Electronics & Hardware Exercise 1.2.15
Electronic Mechanic - Basic Electricity

Construct a test lamp and use it to check mains healthiness

Objectives: At the end of this exercise you shall be able to
• construct a test lamp
• check mains healthiness by using a test lamp.

Requirements
Tools/Instruments Materials
• Test lamp - 1 No • Connector leads - as reqd
• DPIC switch - 1 No • Connector Screw driver 150mm - 1 No
• Pendent lamp holder - 1 No
• 40W / 250V Bulb - 1 No
• Voltmeter 0-500V MI - 1 No

PROCEDURE
Method 1 Method 2

ed
1 Connect two cables in pendent lamp holder. 5 Alternatively corner a voltmeter across mains.

bl I
pu M
2 Fix a 40 watts bulb in th lamp holder. 6 Measure the voltage.

ish
3 Put two terminals of the test lamp on the two terminals 7 See whether supply voltage comes from the mains. If
Re NI
of the DPIC switch as shown in Fig 1. the voltmeter shows supply voltage, the mains
healthiness is good
4 Observe the brightness of the lamp. If the lamp gives
be @

normal brightness, the mains healthiness is good.

o ht
t t rig
No py
Co

_______

34
Electronics & Hardware Exercise 1.2.16
Electronic Mechanic - Basic Electricity

Measure the voltage between phase and ground and rectify earthing
Objectives: At the end of this exercise you shall be able to
• measure the voltage between phase and ground
• rectify defective earth.

Requirements
Tools/Instruments
• Trainees tool kit - 1 Set
• Multi meter - 1 No
• Test lamp - 1 No

PROCEDURE
TASK 1 : Measure the voltage between phase and ground

1 Identify the phase and earth point of a 3 pin AC 230V 5 Switch ‘ON’ the main switch.
socket outlet.

ed
6 Measure the AC voltage and record the value.
2 Mark the three points as P,N & E using sketch pen as

bl I
7 AC voltage is ................................Volt.
shown in Fig 1.
pu M
ish
Rectify the defective earth
Re NI
1 Connect test lamp between earth hole of the 3 pin
socket and phase.
be @

2 See the condition of the brightness in the lamp.

3 If it does not glow, then there is fault inearth connection.
o ht

4 Check the earth wire between socket to earth.

t t rig

5 If there is no defect in the earthline check the earth pit.

6 Check the earth wire connected in the electrode.
No py

3 Check whether earth connections are correct.

7 If there is corrosion, clean the portion at the point of
4 If earth connections are correct insert common terminal
Co

earth connection.
of the multimeter to the phase point and other terminal
of the multimeter to the earth point as shown in Fig.2. 8 Tighten the bold and nut at the point of earth connection.

_______

35
Electronics & Hardware Exercise 1.2.17
Electronic Mechanic - Basic Electricity

Identify and test different AC mains cables

Objectives: At the end of this exercise you shall be able to
• identify the different types of AC mains cables
• test different AC mains cable.

Requirements
Equipments Materials
• Continuity Tester - 1 No • 5 core cable - 1 Meter
• Trainees tool kit - 1 Set • 4 core cable - 1 Meter
• 3 core cable - 1 Meter
• 2 core cable - 1 Meter
• Cotton Waste - as reqd
• Cotton cloth - as reqd

PROCEDURE
TASK 1 : Identify the different type of AC mains cables.

ed
Assumption: Different types of cables with

bl I
pu M
English alphabet as given in this exercise are

ish
displayed on the work bench. Trainees are
Re NI
required to identify the cables.

1 Identify the cable and record its name in the table

be @

Table
o ht

Alphabet Name of the Cable

t t rig

3
A
No py
Co

D
4

_______

36
TASK 2 : Test different AC mains cables.
5

1 Connect the each cable ends between the proper

terminals of multimeter for continuity test.
2 If the reading shows zero, then there is continuity in
the cables. If it shows infinity, there is a break in the
cable.

_______

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.17 37

Electronics & Hardware Exercise 1.2.18
Electronic Mechanic - Basic Electricity

Prepare terminations, skin the electrical wires / cables using wire stripper and
cutter
Objectives : At the end of this exercise you shall be able to
• skin (cut and remove) the insulation of cables using manual stripper and a wire stripper with auto ejection
of insulation.
• strip off the insulation of the PVC sheathed cable using side cutting pliers.
• skin the insulation of three and two core cables
• terminating wire end with crocodile clip and banana plug
• terminating skined cable to a two - pin mains plug
• terminating skined cable to three pin mains plug.

Requirements
Tools/Instruments • Cut pieces of flat twin-core cable -3m
(250 to 300 mm long pieces)
• Trainees tool kit - 1 set
• PVC insulated and PVC sheathed
• Wire stripper: manual & auto - 1 each
cable single core -3m
• Diagonal cutting pliers 150 mm - 1 No
(250 to 300 mm long pieces)
• Hand operated eyelet closing pliers - 1 No
• Cut pieces of round PVC 3 and

ed
Materials 4 -core cable

bl I
(250 to 300 mm long pieces) -3m
•
pu M
Copper and aluminium cables of the

ish
• Two core PVC cable (230V, 5A) -1 m
following sizes:
Re NI
• Two pin electrical mains plug - 1 No
• PVC single strand 1.5 sq. mm -3m
(230V,5A)
• PVC single strand 2.5 sq. mm -3m
• 3 core PVC cable -1m
• PVC cable 14/0.2 mm -3m
be @

• 3 pin electrical mains plug - 1 No

• PVC cable 21/0.2 mm -3m
• PVC cable 40/0.2 mm -3m
o ht
t t rig

PROCEDURE
TASK 1 : Skin the cable insulation using a manual stripper
No py

1 Mark and cut the length of the cable to be trimmed off.

The jaws have V shaped notches to cut the
Co

2 Straighten the ends at which insulation is to be skinned. insulation.

3 Mark the point from which the insulation is to be
skinned. The adjustment screw operates as a stop to
allow for a wide range of wire diameters. (Figs
4 Adjust the jaws of the manual stripper and set them to 1 &2).
suit the gap equivalent to the size of the conductor
core. (Fig 1) 5 Set the jaws at the mark, press the handle of the
stripper and turn to cut the insulation.

Exercise care not to nick the conductor. For

better practice try on small waste pieces

6 Pull the stripper to remove the insulation. (Fig 2)

38
 8 Exercise additional care in the case of flexible cables
Partially cut insulation needs excessive force
so as not to cut even a single strand.
to remove. Excessive force, if required, indi-
cates improper cutting of insulation.
When using this tool, make sure that it is
correctly adjusted before trying to strip the
7 Repeat the skinning of the wire insulation with another
insulation from the cable without damaging the
type of manual wire stripper, shown in Fig 3
conductor.
Do not use this tool to cut metallic conductors.

_______

TASK 2 : Skin the cable insulation using an auto-stripper

ed
1 Mark the length of insulation to be removed from the

bl I
ends.
pu M
ish
2 Straighten the cable ends.
Re NI
3 Study the stripper and its working. (Fig 4)
be @
o ht
t t rig
No py

7 Further pressing makes the required length of

Co

insulation cut from the cable end .

8 Check for nicking of the cable conductor.

4 Select a slot in the jaws whose diameter is equal to the While using this stripper the cable insulation
conductor core diameter. (Fig 5) should be put in the proper slot to avoid dam-
age to the conductor.
5 Locate the jaws of the stripper exactly at the mark.
6 Press the stripper.
_______

TASK 3 : Skin the insulation of three or four core cable

1 Mark out the length up to which the insulation has to be

By cutting too deep into the insulation or sheath
removed from the cable.
of a cable you will cut and, thereby, damage the
2 Hold the cable as shown in Fig 6, place the knife on the insulation of the wires which are inside the
marking to which the sheath or insulation of the cable cable.
has to be removed, and in a circular motion, cut the This can cause short circuits and breakdowns
insulation around the cable to a depth of approximately in electrical installations. (Fig 7)
three quarters of the thickness of the sheath or
insulation.

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.18 39

 Again be very careful not to cut into the
insulation of the wires inside the cable

Alternative method
You can also use a side (diagonal) cutting pliers for
stripping off cable covering
1 Cut the covering from the end up to the length it should
be removed by using side cutting pliers (Fig 9)

3 Place the cable end on a table top, and with the knife, 2 Cut the sheathing along the circumference as shown
slit open the sheath or insulation between the circular (Fig 10)
cut you have made at the end of the cable, as shown.
(Fig 8)

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py

_______
Co

TASK 4 : Terminating wire end with crocodile clip and banana plug

1 Take a piece of tinned red wire and a red crocodile clip.

2 Unscrew and take out the screw and washer from the
crocodile clip.
3 Insert the tinned end of the wire through the leg of the
crocodile clip as shown in Fig 11.

5 Put the screw back on the crocodile clip and tighten the
screw firmly. While tightening hold the wire such that
wire does not protrude below the screw washer as in
Fig 13

4 Bend the tinned exposed conductor to form a loop Excessive wire protrusion results in weak
using a round nose plier. Place the loop in the screw, termination. Hence, the termination may come
such that the loop is in the direction of screw as shown out during usage.
in Fig 12

40 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.18

 9 Insert the loop fully into the hole of the banana plug as
shown in Fig 15 and tighten the screw firmly. Hold the
wire with the body of the banana plug such that the wire
does not slip off while tightening.

6 Get your work checked by your instructor and his

remarks entered in O&T sheet.
10 Holding the banana plug in one hand and the wire in
7 Take a red colour banana plug and unscrew the screw
the other pull the wire gently to ensure that the termi-
on it almost fully but do not take out the screw from it
nation is firm. If termination is found loose, unscrew
place.
the screw, pull out wire and repeat steps 8,9,10.
As the screw is small it will be time consuming 11 Follow suitably steps 1 to 10 above and make different
to replace the screw back in its position if taken types of terminated wires as shown in Fig 16
out from the plug.

8 Bend the other free end of the tinned wire by hand or

ed
using a nose pliers such that it takes the shape of a

bl I
loop as shown in Fig 14.

pu M
ish
Do not press too hard at the bend point as the
Re NI
tinned wire may crack at the bend.
be @
o ht

12 Get your work checked by the instructor.

t t rig
No py
Co

_______

TASK 5 : Terminating skinned cable to a two-pin mains plug

The procedure given below is for the most

common type of two pin PLUG shown in Fig 17.
For other types of plugs the procedure may
vary slightly. Consult Instructor in case of
difficulty.

1 Keep ready the tinned wires.

2 Unscrew the screws on the two-pin plug and keep
them safe. (Use an empty matchbox or a tray)

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.18 41

3 Remove the top cover and terminals of the plug as 8 Place the terminal connected with the red wire at the
shown in Fig 18 and keep them safely in a tray. place marked L in the plug and the other terminal in the
other position of the plug as shown in Fig 21.

9 Spread the wires inside the plug. Place the cable grip
and put back the cable grip screws firmly as shown in
Fig 22a. Get it checked by the instructor.

Some plugs may not have cable grip. In such

case put a simple knot at the entry of the plug
as shown in Fig 22b

4 Remove the cable grip inside the plug and keep it

safely along with its screws.

ed
bl I
Some two-pin plugs may not have cable grips.
pu M
ish
In such cases skip this step.
Re NI
5 Bend the tinned conductors at one end of the two cable
into a loop as shown in Fig.19
be @
o ht

10 Reassemble the plug cover and put back the screw(s).

t t rig

The finished work should look as shown in Fig 23.

No py

Fig 23
6 Unscrew the screw on the terminals of the plug till the
end, but do not remove from the terminal. (Fig 20a)
Co

7 Insert the tinned, looped conductors into the terminals

and tighten the screws firmly as shown in Fig 20b.

11 Get your work checked by the instructor.

_______

42 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.18

TASK 6 : Terminating skinned Cable to three pin mains plug

5 Make loops of the tinned conductor end of wires. Insert

The steps given below are for the most com-
the red wire loop into terminal marked L or Live as
mon type of three-pin PLUGS. For other types
shown in Fig 26a and tighten the terminal screw.
the steps may be vary slightly. Consult your
instructor in case of difficulty. 6 Insert the black/blue wire loop into the terminal marked
N or Neutral and the green wire loop to the earth
1 Open the outer plastic casing of the 3 pin plug. Remove terminal as shown in Fig 26b and tighten screws.
the cable grip and place them safely in a tray or screw
box. Fig 26
2 Check if the length of the outer sheath skinned is equal
to the distance between the earth terminal and the
cable grip as shown in Fig 24. If found less, remove the
required extra length of cable sheath.

Fig 24

7 Position the anti-knik shroud, reassemble the cable

grip rubber and its screws.

ed
8 Get your work checked by the instructor.

bl I
9 Reassemble the top cover of the plug. The finished
pu M
ish
work should look as shown in Fig 27.
Re NI
3 Unscrew the screws on the terminal till the end but do
Fig 27
not remove from the terminal.
be @

4 Remove the anti-knik shroud (anti-knik ring) from the

plug and take the cable through it as shown in Fig 25.
o ht

Fig 25
t t rig
No py
Co

The cables terminated with 2 pin mains plug

and 3 pin main plug made in this exercise will
be used in further exercises. Trainees should
preserve these power cords in their custody.

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.18 43

Electronics & Hardware Exercise 1.2.19
Electronic Mechanic - Basic Electricity

Measuring the gauge of the wire using SWG and outside micro meter
Objectives : At the end of this exercise you shall be able to
• measure the gauge of the wire using
a) standard wire gauge (SW6)
b) outside micrometer.

Requirements
Tools/Equipments/Instruments/Data manuals Materials/Components
• Single strand wire pieces - 2 Nos
• Trainees kit - as reqd • Rigid multistrand wire piece - 1 No
• Standard wire gauge (per batch) - 1 No • Flexible multi strand wire pieces
• Outside micrometer 0-25 mm - 1 No - Red colour - 1 No
(per batch) - Black colour - 1 No
• Pocket table book - as reqd - Green colour - 1 No

PROCEDURE
TASK 1 : Measure the gauge of the wire using standad wire gauge

ed
bl I
1 Clean the skinned wire end conductors of single

pu M
ish
strand wires using dry cloth, straighten the conductors
by hand.
Re NI
Don’t use nose pliers/tweezers to straighten
conductors as this may deform conductors
be @

diameter.
Dust and other particles on the conductor,
o ht

bends and kniks on the conductor give wrong

measurement of the diameter.
t t rig

2 Tag a piece of paper with numbers on each wire piece

No py

as shown in Fig 1. Pick a single strand wire for

measurement of the gauge of the wire.
Co

3 Insert the exposed conductor of the wire into one of the

large holes of the standard wire gauge (SWG) and
take out the wire through the upper slot above that hole
as shown in Fig 2.
4 Repeat step 3 till the conductor exactly fits into the slot 5 Repeat steps 3 and 4 for the other end of the wire.
in Fig 3. In Table-1 record the SWG number printed 6 Get your work checked by the instructor.
below the hole. Remove the conductor by pushing it
down into the hole and pulling it out. 7 Repeat steps 3,4,5 for the other single strand wire.
8 Take the rigid multistrand wire. Clean the conductors
and untwist the twisted strands and separate one of
the strands as shown in Fig 4.
9 For the separated strand of wire, carry out steps 3 & 4
to measure and record the SWG of one strand of the
wire.

44
 10 Count the total number of strands available in that wire
and record it in Table 1
11 Repeat steps 8,9 & 10 for the flexible multistrand
wires.
12 Refer pocket table book and convert the measured
SWG value of wires into diameter of the wires in
inches and millimeters. Record the readings in
Table 1 .
14 Get your work checked by the instructor.

Table 1

WireTag Conductor Conductor Conductor No. of

No. Size of SWG dia. in mm dia.in inches Conductors

END 1 20 0.91 0.036 1

Sample
Entry
END-2 20 0.91 0.036
Single Strand
Wire END-1

ed
1

bl I
END-2
pu M
ish
END-1
Re NI
2
END-2
be @

3
o ht

4
t t rig

Multi-strand 5
Wire
No py

6
Co

_______

TASK 2 : Measure the gauge of the wire using Outside Micrometer

1 Find the least count and zero error of the given mi- 4 Record the reading on the barrel and thimble in table
crometer. Note down the values in Table 2. 2. Loosen the grip on the conductor and take out the
conductor from the micrometer.
2 Take the wire with tag No. 1 for measurement. Clean
and straighten the exposed conductor. 5 Repeat steps 2,3 & 4 for the remaining single strand
and multi-strand wires
3 Place the conductor in the gap between the anvil and
spindle. Turn the thimble till the conductor is just held
Measure the diameter of a single strand in the
between the anvil and the spindle as shown in Fig 5.
case of multi-strand wires.
Turn the rachet till a click sound is heard.
6 Calculate and record the diameter of the wires in mm
Do not over tighten as this may deform the
for which the micrometer readings were noted.
conductor and hence give wrong measurement.

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.19 45

7 Compare the dia. of the wires noted in Table 1 using
a standard wire gauge and the dia. measured using
micrometer. If readings are found not matching consult
the instructor.
8. Get the work checked by the instructor.

Trainees should keep the wires used in this

exercise in their custody as these wires are
reused in further exercises.

Table 2

Least count (LC)

Zero error correction (ZC)

Wire tag Barrel Thimble reading Wire dia. in mm

No. reading (Thimble div x LC) (2) + (3) ± ZC
(1) (2) (3)

ed
bl I
pu M
ish
2
Re NI
be @

3
o ht

4
t t rig
No py

5
Co

_______

46 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.19

Electronics & Hardware Exercise 1.2.20
Electronic Mechanic - Basic Electricity

Refer table and find current carrying capacity of wires

Objectives: At the end of this exercise you shall be able to
• determine the current carrying capacity of copper conductor by referring table
• determine the curent carrying capacity of aluminium conductor by referring table.

Requirements
Materials
• Cotton cloth - as reqd
• Different size of copper conductor cable - as reqd
• Different size of aluminium conductor
cable - as reqd

PROCEDURE
TASK 1 : Determine the current carrying capacity of copper conductor by referring Table 1

1 Determine the current carrying capacity of the given

Assumption: A bunch of different diameters of

ed
copper conductor and note down in Table 2.
copper conductors are to be displayed on the

bl I
work bench. Trainees are required to find out
pu M
ish
the current carrying capacity of wires given
below by referrring the Table 1.
Re NI
be @

Table 1
COPPER AND EQUIVALENT ALUMINIUM CONDUCTOR CABLES CURRENT RATINGS
o ht

Copper Conductor Aluminium Conductor

t t rig

Size of cable Current Rating in Size of cable Current Rating in

No py

amperes Amperes
Co

No & dia Nominal 2-core 3 or 4 core No & dia Nominal 2-core 3 or 4

of wire(mm) area in Cable Core cable in mm area in Cable Core cable
mm2 mm2

47
 Table 2

Size of cable of Copper

Conductor
Current Rating in amperes
No and dia of Normal area in mm2
wire in mm

ed
bl I
pu M
ish
Re NI
2 Determine the copper conductor size for the given current rating and note down in Table 3
be @

Table 3
o ht

Current rating in Amperes Copper Conductor size

t t rig
No py
Co

_______

48 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.20

TASK 2 : Determine the current carrying capacity of the Aluminium conductor
1 Determine the current carrying capacity of the given
aluminium conductor and note down in Table 4.

Table 4

Size of cable of Aluminium

Conductor
Current Rating in amperes
No and dia of Normal area in mm2
wire in mm

ed
bl I
pu M
ish
Re NI
2 Determine the aluminium conductor size for the
given current and note down in Table 5.
be @

Table 5
o ht

Current rating in Amperes Aluminium Conductor size

t t rig
No py
Co

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.20 49

Electronics & Hardware Exercise 1.2.21
Electronic Mechanic - Basic Electricity

Crimp the lugs to wire end

Objectives : At the end of this exercise you shall be able to
• choose the wire
• collect the suitable size of lug
• crimping the lug.

Requirements
Tools/Instruments/Equipments Materials/Components
• Crimping pliers (1mm to 16mm) - 1 No • Lugs 1.5 mm - 6 Nos
• Steel rule 300mm - 1 No • Lugs 2.5 mm - 6 Nos
• Insulated side cutting pliers - 1 No • Lugs 4 mm - 6 Nos
• Electrician Knife - 1 No • Lugs 6 mm - 6 Nos
• Wire stripper auto-eject 200mm - 1 No • Cable 1.5 sq mm,2,5,4,6 length
• Wire stripper (manual) 200 mm - 1 No 300mm - 1No.Each
• Cotton waste - as reqd
• Conducting paste - 1 tube

ed
PROCEDURE

bl I
TASK 1 : Choose the wire
pu M
ish
Re NI
1 Select the wire depending of the application of work.
1
2 Cut the wire 300 mm length from the wire coil as shown
be @

in Fig 1.
3 Get the work checked by the Instructor.
o ht
t t rig
No py
Co

_______

TASK 2 : Collect the suitable size of Lug

1 After finding the cable size, select the correct lug

2
from the table as shown in Fig 2.
2 Show it to your instructor for its correctness.
3 Get the work checked by the Instructor.

_______

50
TASK 3: Crimping the lug

1 After selecting wire and lug select the correct crimping 6 Insert the wire in to the lug as shown in the Fig 6.
tool
6
2 Measure the length of Lug using steel rule.
3 Measure appropriate strip length. Line up the connec
tor barrel to the wire and mark the cable as shown
in Fig 3.

7 Ensure that all wires of the conductor are within the

crimp barrel as shown in Fig 7.

4 Once you have determined the length of the wire strip

the end using wire stripper, being careful not to dam-

ed
age the conductors as shown in Fig 4.

bl I
pu M
ish
4
Re NI
be @

8 Select the appropriate die style to match the installa-

o ht

tion tool. The die index number and color code indi-
cated on the connector should match when the correct
t t rig

die is choosen as shown in Fig 8.

No py

8
Co

5 Check the striped insulation to the proper length,

so that the conductor can be fully inserted into the
connector barrel as shown ing Fig 5.

5
Note:
• Be sure to understand and follow all the
instructions and other materials supplied
with the unit before using tool.
• Be sure to use the tool as instructed so that
your fingers or part of clothing caught in the
tool during crimping operation.

9 Start the crimping tool cycle and hold steady until the
entire cycle is complete. Release ram. Repeat the
same process until all crimp locations on the barrel
have been completed as shown in Fig 9.
Electronics & Hardware : Electronic Mechanic - Exercise 1.2.21 51
 9 10

10 After crimping remove the crimped cable as shown in 11 Get the work checked by the Instructor.
Fig 10.

_______

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

52 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.21

Electronics & Hardware Exercise 1.2.22
Electronic Mechanic - Basic Electricity

Measure AC and DC Voltage using multi meter

Objectives : At the end of this exercise you shall be able to
• measure the AC voltage using multimeter
• measure the DC voltage using multimeter.

Requirements
Tools/Instruments/Equipments Materials/Components
• Digital Multimeter with probes - 1 No • 1.5 dry cell - 1 No
• Auto transfer having input 0-220V • 3.3V CMOS battery - 1 No
AC & output 0-270V/15A - 1 No • 9V battery - 1 No
• 12 V battery - 1 No

PROCEDURE
TASK 1: Measure the AC voltage using multimeter

ed
1 Plug the black probe into the COM port on your
Note : Most multimeters power up in Auto
multimeter as shown in Fig 1.

bl I
range mode. This automatically selects a
pu M
ish
measurement range based on voltage present.
1
Re NI
3
be @
o ht
t t rig
No py
Co

2 Plug the red probe into the VΩmA port as show in

Fig 2.
5 Insert the testing probes into the autotransformer
2 socket as shown in Fig 4.

3 Switch on your multimeter, and set the dial to continuity

mode (indicated by an icon that looks like a sound
wave).
Note: Before power ON auto transformer, set to
4 Turn the multimeter knob to the ACV or AC (v) Voltage 0V, and power ON
section as shown in Fig 3.
6 Power ON the Auto Transformer,

53
7 Increase the voltage 10V in Autotransformer, the Table 1
multimeter will show the voltage range and note down
the voltage on Table -1. S No. AC Voltage

8 Repeat the above steps for other voltages and

notedown the corresponding voltage in mutimeter
9 Get the work checked by the Instructor

_______

TASK 2 : Measure the DC voltage using multimeter

1 Follow the Steps 1 to 3 in task 1.

7
2 Turn the multimeter knob to the DCV or DC/V
Voltage section as shown in Fig 5.

ed
bl I
pu M
ish
Re NI
be @

8
o ht
t t rig

3 Power on the multi meter.

4 Take the 9V battery place the red probe on the positive
No py

terminal, and the black probe on the negative terminal

as shown in Fig 6.
Co

7 Record the multi meter reading in Table II.

Tabel II
S No. DC Voltage

2
5 If your range was set too high, you may not get a very
accurate reading. Here the multimeter reads 9 volts 3
but we can turn the dial to a lower range to get a better
reading as shown in Fig 7. 4
6 With the range set correctly, we get a reading of 9.42
volts as show in Fig 8. 8 Repeat the above steps for other battery and see
the corresponding voltage in multimeter and note
down the reading in Table - II.
9 Get the work checked by the Instructor.
_______
54 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.22
Electronics & Hardware Exercise 1.2.23
Electronic Mechanic - Basic Electricity

Identify the type of meters by dial and scale marking / symbols

Objectives: At the end of this exercise you shall be able to
• identify the type of instruments (AC/DC) and its function from the dial markings
• identify the type of instrument (AC/DC) from the scale marking symbols of the terminal.

Requirements
Tools/Instruments Materials
• Voltmeter 0 - 250 V, DC, MC - 1 No • Connecting leads flexible - assorted sizes
• Voltmeter 0 - 500V, MI - 1 No
• Ammeter 0 - 5A, DC, MC - 1 No
• Ohmmeter 0 - 1000 ohms - 1 No
• Multimeter - 1 No
• Multi-range voltmeter MC/MI - 1 No

PROCEDURE
TASK 1:- Identify the type of instrument (AC/DC) and its function from the dial markings.

ed
1 Identify the function of the instrument by referring to TABLE 2

bl I
pu M
the symbol on the dial. (Fig 1).

ish
Instrument Symbol Function
Record the observation below in Table 1.
Re NI
Figure 1
be @
o ht

Figure 2
t t rig
No py
Co

TABLE 1
Instrument Symbol Function

Figure 1

2 Identify the instruments shown in Figures 1 & 2 for

their types - DC, AC or both, with reference to Fig 3
Record your response in the Table 2.

55
 Fig 4

Fig 5

3 Identify the instruments shown in Figures 4 to 8 as

single or multi-scale / multi-range instruments and
their functions. Record your response in Table 3. Fig 6

TABLE 3

ed
bl I
Instrument Range Scale Function
pu M
ish
Figure 4
Re NI
Figure 5
be @

Figure 6
o ht

Figure 7
t t rig

Figure 8
No py

4 Identify the working position, accuracy (error of indica-

tion), type & range of instrument in Fig 1 & 2 and record
Co

in Table 4.

Table 4

Instrument Type symbol Function symbol Error symbol Working position

Figure 1

Figure 2

56 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.23

 Fig 7 Fig 8

5 Identify the given instrument from the laboratory and

fill up Table 4.

The serial number of the instrument and other

distinct marks should be entered under the
`instrument' column.

ed
bl I
pu M
ish
Re NI
_______
be @

TASK 2 : Identify the type of instrument (AC/DC) from the marking on the terminals.
o ht

1 Identify the connecting terminals of the instrument in

t t rig

Fig 10
the given Figs 9 to 11.
2 Note down the marks in the terminals shown in Figs 9
No py

to 11 and record in Table 5.

Co

Fig 9

If the terminals are marked (+) and (–) or

anyone of them is coloured red, the meter
normally is a DC or MC meter.
If there is no terminal marking, then the meter
normally is an AC/DC or MI-meter.

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.23 57

Fig 11 3 Identify the type of instrument and record it in Table 5.
4 Identify the given instruments from the laboratory and
fill up Table 5.
(The instrument serial number or other distinct marks
should be entered under the column–Instrument No.)

Table 5

Instrument No. Polarity Function Type

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

_______

58 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.23

Electronics & Hardware Exercise 1.2.24
Electronic Mechanic - Basic Electricity

Demonstrate various analog measuring instruments

Objectives: At the end of this exercise you shall be able to
• select various analog measuring instruments
• demonstrate various analog measuring instruments.

Requirements
Equipments
• MC Ammeter 0-5A - 1 No • MI Voltmeter 0-500 V - 1 No
• MI Ammeter 0-10A - 1 No • Wattmeter 0-1500W - 1 No
• MC Milli ammeter 0-1 A - 1 No • Power Factor meter 0.5 lead
• Watt meter 0-400 kW - 1 No - 0-0.5 lag - 1 No
• MC Milli volt meter 0 - 100mV - 1 No • Mega ohmmeter 0-10 Mega ohm - 1 No
• MC voltmeter 0-50V - 1 No Materials
• Frequency meter 45-55Hz - 1 No
• Cotton Waste -as reqd

PROCEDURE

ed
TASK 1 : Demonstrate various analog measuring instruments.

bl I
pu M
ish
Assumption: A set of analog measuring instru-
Re NI
ments as given in this exercise are to be dis-
played on the work bench. Instructor may dem-
be @

onstrate various analog measuring instruments

such as milli ammeter, ammeter, milli voltme-
ter, voltmeter, wattmeter, Frequency meter,
o ht

power factor meter etc to trainees.

t t rig

1 After demonstration ,the instructor may ask the trainees

to identify the measuring instruments and draw the dial
No py

sketch in the allotted column of Table 1.

Co

Table 1

Name of the Meter Dial Sketch

1 MC ammeter

2 Watt meter

59
 Name of the Meter Dial Sketch

3 MC Milli voltmeter

4 Mega Ohmmeter

5 Freqency meter

6 MI Voltmeter

ed
bl I
pu M
ish
Re NI
7 Watt meter
be @
o ht
t t rig

8 MC Milli ammeter
No py
Co

9 Power Factor meter

10 MI Ammeter

11 MC Voltmeter

60 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.24

1 5

6
2

ed
bl I
pu M
ish
7
3
Re NI
be @
o ht
t t rig
No py
Co

8
4

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.24 61

 9 11

10

ed
bl I
pu M
ish
Re NI
_______
be @
o ht
t t rig
No py
Co

62 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.24

Electronics & Hardware Exercise 1.2.25
Electronic Mechanic - Basic Electricity

Find the minimum and maximum measurable range of the meter

Objectives: At the end of this exercise you shall be able to
• determine the minimum and maximum measurable range of the meter.

Requirements
Tools & Instruments Materials
• Lead acid battery 12V - 1 No • Connecting cable copper 1.5mm2 - as reqd
• Trainees tool kit - 1 Set • Cotton cloth - as reqd
• MC ammeter 0-500 mA - 1 No • Variable types of resistor - 2 Nos
• MC voltmeter 0-10V - 1 No • SP Switch 6A, 240V - 1 No

PROCEDURE
1 Collect ammeter, voltmeter, variable resistance bat- 6 Gradually increase load to 500 mA by varying
tery and SP switch. variable resistance.
2 Form th circuit as shown in Fig 1. 7 Also adjust the voltage across load resistor to 10

ed
volts.

bl I
pu M
ish
8 Note down the maximum measurable range of
millammeter and voltmeter and record it in Table 1.
Re NI
Table -1
be @

1 Minimum range of milli ammeter _________

o ht

2 Minimum range of volt meter ____________

3 Maximum range of milliammeter__________
t t rig

4 Maximum range of voltmeter ____________

3 Set the variable resistance to have zero out.
No py

4 Close the switch ‘S’.

Co

5 Note down the minimum measurable range of

miliammeter and voltmeter and record in the Table 1.

_______

63
Electronics & Hardware Exercise 1.2.26
Electronic Mechanic - Basic Electricity

Carryout Mechanical Zero setting of a meter

Objectives: At the end of this exercise you shall be able to
• carry out mechanical zero setting of a meter.
• measure the voltage of a dry cell using a single range voltmeter.

Requirements
Tools/Instruments Materials / Components
• MC Voltmeter 0-5V - 1 No • Dry cells of different voltage range - as reqd
• MC Voltmeter 0-15V - 1 No • Lead acid battery 12V 60 Ah - 1 No
• Screw driver 150mm with 3mm blade - 1 No

PROCEDURE
TASK 1 : Carry out Mechanical zero setting of a meter

1 Take a MC Voltmeter 0-5V and check whether the 5 Take a suitable screw driver to turn the Mechanical
meter needle moves freely on the graduated scale. zero adjustment screw fitted on the meter.

ed
If the needle is not moving freely consult your 6 Turn the screw slowly in steps as shown in Fig 2 until

bl I
instructor
pu M the needle reaches exactly the ‘0’ marking of the scale.

ish
7 Check the meter, whether it is suitable to measure the
Re NI
2 Place the meter on the table. Check whether the voltage of source.
needle is pointed exactly on the zero position of the
be @

meter scale as shown in Fig 1a.

3 If the pointer is exactly on the zero marking of he scale,
o ht

the mechanical zero setting of the meter is proper.

4 If the pointer isnot pointing exactly on the zero marking
t t rig

as in Fig 1(b) & (C) the meter has the Mechanial Zero
error.
No py
Co

8 Get your work checked by the instructor.

_______

64
TASK 2 : Measure the voltage of drycell & lead acid battery using single range voltmeter from the given
lot

1 Take any one of dry cell from the given lot Clean
its terminals using cloth. If the pointer deflects reverse direction on
the scale the identified cell polarity is wrong.
2 Identify the +ve and -ve terminals of the cell. Recheck and interchange connection.
3 Touch the -ve meter prod (Black) to the -ve terminal of
the cell as shown in Fig 3. 5 Note down the voltmeter reading.

4 Also touch the +ve prod (Red) to the +ve terminal of 6 Repeat the steps for the remaining cells and lead
the cell as shown in Fig 3. acid battery and write down the voltmeter reading.

ed
bl I
pu M
ish
_______
Re NI
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.26 65

Electronics & Hardware Exercise 1.2.27
Electronic Mechanic - Basic Electricity

Check the continuity of wires, Meter Probes and Fuse etc

Objectives: At the end of this exercise you shall be able to
• check the continuity of a 1.5 sqmm PVC wire
• check the continuity of multimeter probes
• check the continuity of a glass fuse wire.

Requirements
Tools / Instruments Materials
• Trainees tool kit - 1 Set • Miniature lamp holder with 12V lamp - 1 No
• Digital Multimeter - 1 No • PVC wire 2.5 sq mm - 1 Meter
• Continuity tester - 1 No • PVC wire 1.5 sqmm - 1 Meter
• Wire striper - 1 No • Multimeter Probes - 1 Pair
• 5 Amps Glass fuse wire - 1 No
Equipment / Machinery
• Battery pack / Lead acid Battery 6V - 1 No

PROCEDURE

ed
TASK 1 : Check the Continuity of a 1.5 sqmm PVC wire

bl I
pu M
ish
1 Remove the insulation of the given 1.5 sqmm
Re NI
PVC wire using wire stripper at both ends as shown in
Fig 1.
be @
o ht
t t rig

2 Connect crocodile clips at the free ends of the wire

No py

as shown in Fig 2. 4 Observe the lamp. The lamp glows if wire has conti-
nuity and the lamp does not glow if wire has
Co

3 Connect other ends to the continuity tester and

check the continuity of the given wire. break or cut.
5 Instead of continuity tester a multimeter can also
be used to find out the continuity.

_______

TASK 2 : Check the continuity of a multimeter Probe

1 Connect any one of the meter probe between lead

acid batttery terminals through a switch and
miniature lamp as shown in Fig 3.
2 Close the SPST switch observe the lamp. If there is
a continuity in the probe the lamp will glow and if the
lamp does not glow there is a break.

_______
66
TASK 3 : Check the continuity of a glass fuse wire

1 Pick one glass fuse wire from section.

2 Set a multimeter to resistance setting.
3 Connect the probes to two ends of the fuse as
shown in Fig 4.
4 If the reading is between 0 and 5 ohms the fuse is
good. A higher reading indicates a bad or degraded
fuse. A reading of OL (over limit or infinity) definitely
means a blown fuse wire.
5 Repeat the same procedure for some other glass
fuses also.
6 Get the work checked by the instructor.

_______

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.27 67

Electronics & Hardware Exercise 1.2.28
Electronic Mechanic - Basic Electricity

Measure voltage and current using Clamp meter

Objectives: At the end of this exercise you shall be able to
• measure AC voltge using clamp meter
• measure DC voltage using clamp meter
• measure AC current using clamp meter
• measure DC current using clamp meter.

Requirements
Tools / Instruments/ Equipments
• Clamp meter with jaws / Clamp meter
with flexible current probe - 1 No

PROCEDURE
TASK 1 : Measure AC voltage using Clamp meter

1 Connect the black test lead to the COM terminal.

ed
2
2 Plug the red probe into the VΩmA port.

bl I
pu M
ish
3 Turn the rotary function switch to ACV/ voltage
Re NI
section as shown in Fig 1.
be @

1
o ht
t t rig

7 View the reading on the display and note down

No py

voltage.
Co

8 Repeat step 4 for all other test point and note d o w n

the voltage.
9 Get the work checked by the Instructor.
4 Select the required Range of the voltage range.
AC Voltage = ____________________(V)
5 Turn on the Clamp meter.
6 Measure the voltage by touching the probes to the
desired test points of the circuit as shown in Fig 2.

_______

68
TASK 2 : Measure DC voltage using Clamp meter

1 Follow the Steps 1 to Step 2 in task 1.

4
2 Turn the rotary function switch to DCV/v voltage
section as shown in Fig 3.

5 View the reading on the display and note down

voltage.
6 Repeat step 4 for all other test point and note d o w n
the voltage.
3 Turn on the Clamp meter. 7 Get the work checked by the Instructor.
4 Measure the voltage by touching the probes to the DC voltage: ______________________(V)
desired test points of the circuit as shown in Fig 4.

ed
_______

bl I
pu M
ish
TASK 3 : Measure AC current using Clamp meter
Re NI
1 Follow the steps 1 to Step 2 in task 1.
6
be @

2 Turn the rotary function switch to ACA/A current sec-

tion as shown in Fig 5.
o ht

5
t t rig
No py
Co

8 Open the clamp by pressing the jaw release as

shownin Fig 7.

7
3 Determine the current to be measured in AC or DC.
4 Select the required range of the ampere range.
5 Turn on the Clamp meter.
6 Determine the Phase conductor in cable and separate
the cables.
7 Check the Jaws. The Current flow direction will be
showing as shown in Fig 6.

9 Insert the conductor to be measured into the clamp as

shown in Fig 8.

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.28 69

 8 Note: Don’t insert all the conductors in the
Jaw

10 Enclose a single conductor inside the jaws. Make

certain the jaws are completely closed before taking
readings.
11 View the current reading on the main display and
note down the current.
12 Repeat the above steps for all other conductors to
measure the current.
13 Get the work checked by the Instructor.
AC Current =_______________Ampere

_______

TASK 4 : Measure DC current using Clamp meter

1 Follow the Step 1 to Step 2 in task 1.

11
2 Turn the rotary function switch to DC A Current sec-
tion as shown in Fig 9.

ed
bl I
9

pu M
ish
Re NI
be @
o ht

8 Insert the conductor to be measured into the clamp

as shown in Fig 12.
t t rig

Note: Don’t insert all the conductors in the

No py

Jaw.
3 Select the required range of the DCA range.
Co

4 Turn on the Clamp meter. 12

5 Determine the battery phase conductor cable .

6 Check the Jaws. The Current flow direction will be
showing as shown in Fig 10.

10

9 Enclose a single conductor inside the jaws. Make

certain, the jaws are completely closed
before taking readings.
10 View the current reading on the main display and note
down the current.
11 Repeat the above steps for all other conductors to
7 Open the clamp by pressing the jaw release as measure the current.
shown in Fig 11.
12 Get the work checked by the Instructor.
_ _ _ _ _ _ _ Battery Current =______________(mA)
70 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.28
Electronics & Hardware Exercise 1.2.29
Electronic Mechanic - Basic Electricity

Identify the +ve and -ve terminals of the battery

Objectives: At the end of this exercise you shall be able to
• determine the polarity of a battery using a MC voltmeter
• find the polarity of a DC supply (above 80V) with a neon tester.

Requirements
Tools/Instruments Materials
• Voltmeter 0-15V MC - 1 No • Connecting leads flexible - as reqd
• Voltmeter 0-300 MC - 1 No • Test prods - 2 Nos
Equipment/Machines
• Lead Acid Battery 12V - 1 No

PROCEDURE
Checking battery terminals

4 Result : Is the pointer deflects normally to indicate the

ed
1 Connect test leads to the MC voltmeter of 15V FSD.
voltage of the battery?.

bl I
2 Touch one test lead from the +ve terminal of the
pu M
ish
voltmeter firmly on one of the terminals of the battery If your answer is 'Yes' go to step 5.
and the other test lead from the negative terminal of If your answer is 'No' the pointer deflects in the reverse
Re NI
the voltmeter on the other terminal of the battery for direction (ie) showing less than zero voltage. Go to
just a while.(Fig 1). step No.7.
be @

5 If the pointer deflects to indicate the voltage of the

battery, again place the second test lead on the
o ht

terminal. Now the voltmeter will indicate the voltage of

the battery.
t t rig

6 Mark the polarity of the battery as that of the voltmeter

the +ve terminal of the voltmeter that touches the
No py

battery terminal as +ve terminal and the -ve terminal

of voltmeter that touches the battery terminal as -ve
terminal.
Co

3 Observe the deflection of the pointer of the MC 7 If the deflection is reverse and the pointer kicks
voltmeter. backward, do not try again.

_______

71
Electronics & Hardware Exercise 1.2.30
Electronic Mechanic - Basic Electricity

Identify the rated output voltage and Ah capacity of given battery

Objectives: At the end of this exercise you shall be able to
• Identify the rated output voltage and Ampere hour capacity of given battery.

Requirements
Equipments Materials
• Lead acid battery 6V - 1 No • Connecting cables - as reqd
• Lead acid battery 12V - 1 No • Test prods - 1 set
• MC Voltmeter 0-15V - 1 No

PROCEDURE

1 Read and record the name plate details shown in a 4 Identify the Ampere hour capacity and record it in the
given lead acid battery (Fig 1). Table -1.
5 Repeat this procedure for other battery.
1
6 Show the readings to your instructor and get his

ed
approval.

bl I
pu M
ish
Table 1
Re NI
Name plate details
Manufacturer Name: .................................................
be @

Type: .........................................................................
Model : ......................................................................
o ht

No. of Cells: .............................................................

t t rig

2 Identify the rated output voltage and record it in the Rated output volage: .................................................
Table -1. Ah Capacity: ..............................................................
No py

3 Touch the voltmeter terminals across battery terminal

Co

and read the meter reading to verify the correctness of

the rated voltage written in the name plate.

_______

72
Electronics & Hardware Exercise 1.2.31
Electronic Mechanic - Basic Electricity

Measure the voltages of given cells / battery using Analog / Digital Multimeter
Objectives: At the end of this exercise you shall be able to
• measuring the voltage of the given battery using Analog Multimeter
• measuring the voltage of the given cells using Digital Multimeter.

Requirements
Tools / Equipments/ Instruments Materials/components
• Digital Multimeter Probe - 1 No • Lead acid battery 6V/12V 100Ah - 1 No
• Analog Multimeter with probe - 1 No • 1.5V/3.3V battery - 1 No

PROCEDURE
TASK 1 : Measuring the voltage of the given battery using Analog Multimeter

1 Insert the black probe of Analog multimeter in the

3
“COM” or “-”jack.

ed
2 Insert the red probe in the “V” or “+” jack as shown

bl I
in Fig 1.
pu M
ish
Re NI
1
be @
o ht
t t rig

• You would use 50 meter range and that will

be the actul range.
No py

• This means 10=10, 30=30 etc.

Co

• The minor increments is 1V DC.

3 Set the multi meter to V-, V---, DCV, or VDC as • The meter readings is approximately 24 V DC as
shown in Fig 2. shown in Fig 4.
2
4

4 Set the meter for the measuring voltage range

5 Hold the probes on your hand.
provided for DC Volts, now we are setting 50V as
shown in Fig 3. 6 Place the black probe on the negative (-) terminal of
the battery, and red probe on the positive (+)
terminal of the battery as shown in Fig 5.

73
 5 6

7 Make sure the probes have good contact with ends. 10 Note down the reading.

8 You can use your fingers to press the metal tips of 11 Get the work checked by the Instructor
the probe to the battery. Given battery Voltage -----------------------(V)
9 Check your Analog voltmeter reading as shown in
Fig 6.

_______

TASK 2 : Measuring the voltage of the given cells using Digital Multimeter

ed
bl I
pu M
1 Plug the black probe into the COM port on your

ish
3
multi meter as shown in Fig 1.
Re NI
1
be @
o ht
t t rig
No py

Note: Most multi meters power up in Auto

Co

range mode. This automatically selects a

masurement range based on voltage present.
2 Plug the red probe into the VΩmA port as shown in
4 Turn the knob to 20 V as shown in Fig 4.
Fig 2.
4
2

5 Hold the probes in each hand.

3 Turn the multi meter knob to the DCV or DC(V)
Voltage section as shown in Fig 3. 6 Identify the battery positive terminals and negative
terminals as shown in Fig 5.

74 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.31

 9 Make sure the probes have good contact with ends.
5
10 You can use your fingers to press the metal tips of
the probe to the battery.
11 Check your Digital voltmeter reading.
12 The voltage read out will display on the mutimeter
as shown in Fig 7.

7 Touch the metal tip of black probe to the battery’s

ground or negative end, marked with “-”
8 Touch the metal tip of the red probe to the battery’s
positive end, marked with a “+” as shown in Fig 6.

13 Get the work checked by the Instructor.

Given battery Voltage -----------------------(V).

ed
bl I
pu M
ish
Re NI
be @
o ht

_______
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.31 75

Electronics & Hardware Exercise 1.2.32
Electronic Mechanic - Basic Electricity

Charge and discharge the battery through load resistor

Objectives : At the end of this exercise you shall be able to
• measure the specific gravity of the electrolyte
• check the voltage of each cell with a voltmeter
• check the level of the electrolyte and top up
• determine the battery condition with a high rate discharge (H R D) tester after one hour charge
• check and clean the battery terminals
• connect and charge the battery by the constant current method
• connect and charge the battery by the constant potential method
• test the battery for its charged condition.

Requirements
Tools/Instruments • Lead acid battery 12 volts - 1 No
• Lamp Bank (240V, 1KVA) - 1 No
• Voltmeter 0-15V MC - 1 No
• DPIC 16A - 1 No
• Ammeter 0-10A MC - 3 Nos
• Hydrometer - 1 No Materials
• High rate discharge tester - 1 No
• Distilled water (450ml) - 1 Bottle

ed
Equipment/Machines • Petroleum jelly - as reqd

bl I
• Sandpaper - as req
• 12V Battery charger
pu M - 1 No

ish
• Test leads with crocodile clips - 1 pair
• Low voltage DC power
• Hydrogen peroxide - as reqd
Re NI
supply (0-3V) 10A - 1 No
• Clips - 1 pair
• Variable resistor 10 ohms,
5A capacity - 2 Nos
be @
o ht

PROCEDURE
TASK 1 : Charging a battery using a battery charger
t t rig

1 Clean the battery terminals, if corroded, with sandpaper:

No py

if sulphated, clean with wet cotton waste or with soda

bicarbonate.
Co

Do not damage the battery terminal by scraping

with any metal strip.

2 Unscrew all the vent plugs and check the level of the
electrolyte.

Do not clean the battery top surface keeping

the vent plugs open. The accumulated dirt may
fall inside the cells and form sediments.
6 Measure the cell voltage and the battery voltage with
3 Top up the electrolyte to the marked level in all the cells a voltmeter and record in the Table 1.
with distilled water.
Do not use a high rate discharge tester for
4 Keep Hydrometer inside and Pump electrolyte upto measuring voltage.
reference mark.
5 Check the initial specific gravity of the electrolyte of 7 Connect the battery charger's +ve lead to the +ve
each cell using a hydrometer (Fig 1) and record in terminal of the battery and the -ve lead of the charger
Table1. to the -ve terminal of the battery. (Fig 2).
8 Adjust the battery charger output voltage equal to or
a little higher than the voltage of the battery to be
charged.

76
 11 Disconnect the battery when fully charged. Fit the
vent plugs, clean the outer surface with wet cloth.
Apply petroleum jelly to the terminals.
12 Check the battery for its working voltage under load
using a high rate discharge tester for a short period.
(Fig 3).

9 Set the charger voltage to produce the determined

value of initial charging current.

Follow the manufacturer's recommendation for

current setting for charging as well as
discharging.
Do not keep a high rate discharge tester for a

ed
10 Observe the voltage of each cell of the battery and long period, say more than five seconds.

bl I
pu M
specific gravity of the electrolyte at regular intervals

ish
(say ONE hour).
Re NI
Remove the vent plug to enable the gas to
escape.
be @
o ht

Table 1
t t rig

Cell No. Initial condition Changed condition after

Specific Gravity Voltage

No py

1 Hr 2 Hr 3 Hrs 4 Hrs 5 Hrs

SP V SP V SP V SP V SP V
Co

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.32 77

TASK 2 : Charge a battery by constant current method

1 Form the circuit as shown in Fig 4. 3 Check the level of the electrolyte and top up.
4 Check the specific gravity and voltage of each cell and
record, before charging, in Table 2. (Prepare a blank
table as shown in Table 1).
5 Connect the given batteries in series with the lamp
bank as per Fig 4.
6 Adjust the current rating through the lamp bank..
7 Set the lamp bank to produce the determined value of
the initial charging current.

Don't touch the battery terminals since the

circuit is connected to 230 V DC.
Proper protective devices should be provided
in the circuit.

8 Read the voltage and specific gravity of each cell at

2 Clean the battery terminals and unscrew all the vent regular intervals and record in Table 2.
plugs.
9 Repeat the steps 10 and 11 of Task 1.

ed
bl I
_______

pu M
ish
Re NI
TASK 3 : Charge a battery by constant potential method.
be @

1 Form the circuit as shown in Fig 5. 4 Read and record the voltage, current and specific
gravity at regular intervals in Table 3. (Prepare a blank
o ht

table as shown in (Table 1).

5 Repeat the steps 10 and 11 of Task 1.
t t rig

Conclusion
No py

Compare the constant current method and the constant

potential method with reference to
Co

a) power wasted during charge.

_____________________________________________
________________________________________________
_____________________________________________
2 Repeat the steps 2 to 4 of Task 2. b) time taken to charge.
3 Adjust the voltage by adjusting the rheostat to the _____________________________________________________
required value.
________________________________________________
_____________________________________________

_______

78 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.32

TASK 4 : Discharge the battery through load resistor

1 Form the circuit as shown in Fig 6. 5 Read and record, the curent voltage and specific
gravity at regular interval say one hour in Table 2.

Do not discharge the battery beyond the

minimum value of voltage say 1.75V.

6 Check the specific gravity and voltage after discharge.

7 Check and compare the differences of specific gravity
and voltage before and after discharging the battery.
2 Check up the level of the electrolyte and topup. 8 Stop the discharge when the battery reaches below
3 Connect the load resistor to the battery. 1.75 volts.

4 Check the specific gravity and voltage before 9 After discharge, recharge the battery immediately.
discharging.

Table 2

Time after Load Current Changed Condition after Discharge

1 Hour I in amps
Specific Gravity Voltage

ed
bl I
1 Hr
pu M
ish
Re NI
2 Hrs
be @

3 Hrs
o ht

4 Hrs
t t rig

5 Hrs
No py

6 Hrs
Co

7 Hrs

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.3.32 79

Electronics & Hardware Exercise 1.2.33
Electronic Mechanic - Basic Electricity

Maintain the Secondary Cells

Objectives : At the end of this exercise you shall be able to
• check the battery type, voltage and rating
• inspection of the battery
• battery testing
• battery watering
• battery cleaning
• battery charging.

Requirements
Tools/ Equipments/Instruments Materials / components
• Trainees tool Kit - 1 Set • Lead acid battery 6V/12V 100 Ah - 1 No
• Hydrometer - 1 No • Distilled water 500 ml - as reqd
• MC voltmeter (0-15V) - 1 No • Petroleum jelly - as reqd
• Multimeter with Probe - 1 No • Cleaning cloth - as reqd
• Cleaning brush 2 inch - 1 No
• Goggles - 1 No

ed
• Gloves - 1 No
• Baking soda - as reqd

bl I
pu M
ish
Re NI
PROCEDURE
TASK 1 : Check the battery type voltage and current rating
be @

Caution: Always wear the necessary protective 2 Check the battery type, voltage and current rating
o ht

clothing when working with a battery, especially and note down the details in Table - I.
gloves and safety glasses. 3 Get the work checked by the Instructor.
t t rig

1 Look the battery label marking.

No py

Table - 1
Co

Sl No. Battery Type Voltage Current Ratting

_______

80
TASK 2 : Inspection of the battery

1 Examine the outside appearance of the battery. 6 Many battery problems are caused by dirty and
loose connections.
2 Check the battery covers and rack should be clean.
• Look closely for loose or damaged parts
3 Any fluid in and around the battery may be an
indication that elctrolyte is spilling 0r leaking out. • Battery cables should be intact. Broken
or frayed cables can be extremely hazard
4 Keep the terminals and connectors clean.
ous.
5 Check cabels, clamps, and housing for obvious
7 Tight all wiring connections.
damage or loose connections.
8 Get the work checked by the Instructor.

_______

TASK 3 : Battery Testing

1 Discount all loads from the batteries. 3 Check the rate of charge as mentioned in the Table II
2 Measure the Voltage using Digital multimeter. 4 Get the work checked by the Instructor.

Table - II

ed
bl I
Specific gravity Open - Circuit Voltage
Percentage of
pu M
ish
Charge corrected to
Re NI
6V 8V 12V 24V 36V 48V
be @

100 1.277 6.37 8.49 12.73 25.46 38.20 50.93

o ht

90 1.258 6.31 8.41 12.62 25.24 37.85 50.47

t t rig

80 1.238 6.25 8.33 12.50 25.00 37.49 49.99

No py

70 1.217 6.19 8.25 12.37 24.74 37.12 49.49

Co

60 1.195 6.12 8.16 12.27 24.48 36.72 48.96

50 1.172 6.02 8.07 12.10 24.20 36.31 48.41

40 1.148 5.98 7.97 11.89 23.92 35.87 47.83

30 1.124 5.91 7.88 11.81 23.63 35.44 47.26

20 1.098 5.83 7.77 11.66 23.32 34.97 46.63

10 1.073 5.75 7.67 11.51 23.02 34.52 46.03

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.2.33 81

TASK 4 : Battery Watering

1 Open the vent caps and look. 5 Once charging is completed, open the vent caps
and look inside the cell.
2 Check the electrolyte inside the battery electrolyte
level. If low fill with distilled water (never refill with 6 Add water until the electrolyte level is 1/18” above
electrolyte). the cells...
Green = No water is required. 7 A piece of rubber can be used safely as a dipstick to
help determine this level.
Clear or White = Water is required Fig 1.
8 Clean, replace, and tighten all vent caps.
3 If necessary add enough water to cover the plate.
9 Get the work checked by the Instructor.
4 Put batteries on a complete charge before adding
any additional water.
_______

TASK 5 : Battery Cleaning

1 Check that all vent caps are tightly in their place. 6 Coat the battery with grease made for high tem-
peratures as shown in Fig 2.
2 Clean the battery top with a cloth or brush or a
solution of baking soda and water.
2
3 Clean with water and dry with a clean cloth.

ed
Note: When cleaning do not allow any clean-

bl I
pu M
ing solution or other foreign matter to get in-

ish
side the battery.
Re NI
4 Remove the connectors from the battery terminal by
be @

moving them from side to side and gently pulling

them up.
o ht

5 Rub the wire brush into a paste of baking soda

mixed with distilled water as shown in Fig 1.
t t rig

7 Reconnect the clamps to the terminals.

1
8 Keep the area around batteries clean and dry.
No py

9 Get the work checked by the Instructor.

Co

_______

82 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.33

Electronics & Hardware Exercise 1.2.34
Electronic Mechanic - Basic Electricity

Measure the specific gravity of electrolyte using hydro meter

Objectives: At the end of this exercise you shall be able to
• Connect the battery charger with the lead acid battery
• Measure the specific gravity of electrolyte.

Requirements
Tools / Equipments Materials
• Lead acid battery 12V, 60 Ah - 1 No • Distilled Water 500 ml - 1 Bottle
• Battery charger 12V - 1 No • Concentrated sulphuric acid - 200 ml
• Hydrometer - 1 No • Clean Jar for mixing 1 Ltr.capacity - 1 No
• MC voltmeter 0-15V - 1 No
• MC Ammeter 0-5A - 1 No

PROCEDURE
1 Unscrew all the vent plungs and check the level of the 5 In a fully charged lead acid cell the specific grav
electrolyte. ity of the electrolyte should be 1.28 at room tem

ed
perature of 70° to 80° F.
Don’t clean the battery top surface keeping the

bl I
pu M
vent plugs open . The accumulated dirt may 6 When the specific gravity of electrolyte falls down

ish
fall inside the cells and form sediments. to about 1.150 the cell can be taken as fully dis
Re NI
charged.
2 Insert the hydrometer inside the battery. 7 Connect the battery charger with lead battery (Fig 2)
be @

3 Pump the electrolyte upto reference mark. 8 Every one hour measure the specific gravity and
4 Check the initial specific gravity of the electrolyte record it in Table 1.
o ht

of each cell using hydrometer as shown in Fig 1 9 Repeat the steps 7 & 8 for 4 more hours and
and record it in Table 1. record the value in Table 1.
t t rig
No py
Co

83
 Table 1

Changed condition after

Cell No. Initial Specific
Gravity 1 Hr 2 Hrs 3 Hrs 4 Hrs 5 Hrs

SP SP SP SP SP

ed
bl I
pu M _______

ish
Re NI
be @
o ht
t t rig
No py
Co

84 Electronics & Hardware : Electronic Mechanic - Exercise 1.2.34

Electronics & Hardware Exercise 1.2.35
Electronic Mechanic - Basic Electricity

Test a battery and verify whether the battery is ready for use or needs
recharging
Objectives : At the end of this exercise you shall be able to
• test a battery and verify whether the battery is ready for use
• verify whether battery needs recharge.

Requirements
Tools/Instruments Materials
• High rate discharge tester - 1 No • cotton waste - as reqd
• Hydrometer - 1 No • Test leads with crocodile clip - 1 Pair
• MC voltmeter 0-15V - 1 No
Equipment/Machines
• Battery lead acid type 12V - 1 No

PROCEDURE

ed
TASK 1 : Test a battery and verify whether the battery is ready for use

bl I
pu M
ish
1 Measure the cell voltage and battery voltage with a 7 If all the above test results are satisified, then the
Re NI
voltmeter. battery is ready for use.
2 See whether each cell voltage is 2.6V.
be @

3 Measure the specific gravity of electrolyte of each

cell with a hydrometer.
o ht

4 See whether the specific gravity is 1.28.

t t rig

5 Check the level of the electrolyte in the battery.

6 See whether the level of electrolyte is above the
No py

level of eletro plate.

Co

_______

TASK 2 : Verify whether battery needs recharge

1 Check the battery for its working voltage under

load using a high rate discharge tester for a short
period say within 5 seconds.
2 See whether each cell voltage is below 1.8V.
3 Measure the specific gravity of electrolyte of each
cell with a hydro meter.
4 See whether the specific gravity is below 1.24.
5 If all the test results are in the above condition then
the battery needs recharge.

_______
85
Electronics & Hardware Exercise 1.3.36
Electronic Mechanic - Measuring Technique

Use the multimeter to measure the various functions (ACV, DCV, DCI, ACI, R)
Objectives: At the end of this exercise you shall be able to
• select and connect proper coloured test prods in the multimeter
• select the right position of the function switch for the type of voltage or current being measured
(AC/DC)
• set the multimeter to the right measuring range, using the selector switch
• connect the multimeter to the measuring object/circuit
• measure the voltage or current using the multi-scale in the dial
• make voltage and current measurements observing the necessary safety rules
• select the resistance range, set the zero ohm position and measure the resistance.

Requirements
Tools and Instruments Materials
• Multimeter with test prods - 1 No • D.P.S.T knife switch 16A 250V - 1 No
• Long nose pliers 150mm - 1 No • Tag board - 3 Nos
• Tweezer 150mm - 1 No • Resistor 1/2 Watt 200 ohms, 680 ohms,
• Soldering iron 25 W,230V - 1 No 1.5K,3.3K,4.7K and 330K - each 1 No
• Nipper pliers 150mm - 1 No • Resistor 27 ohms 5 W, 2K ohms

ed
• Combination pliers 200mm - 1 No 1 W, 6.8 ohms 20 W - each 1 No

bl I
• Solder sucker
pu M - 1 No • Resistor 15 ohms 10 W, 15K

ish
1/2W 150 ohms 2 W - each 2 Nos
Equipment/Machines
Re NI
• Resin cored solder 60/40 - 20 grams
• Auto-transformer having input • SPST knife switch 16A with
0-220V AC, and output 0-270V/5 A - 1 No fuse arrangement - 2 Nos
be @

• Battery 12 V, 60 AH or variable - 1 No • Crocodile clips 16 amps - 2 Nos

power supply unit 0-30V/DC 2 A • Fuse wire 5 amps
o ht

1 Amp - 200 mA Glass - as reqd

Catridge with holder
t t rig

PROCEDURE
No py

TASK 1 : Measurement of DC voltage using a multimeter

Co

1 Prepare the resistor board using tag board and resis- 2 Collect a multimeter.
tors as shown in Fig 1 and connect with the supply
through the fuse and SPST knife switch. Identify and investigate the use of the function
switch, range switch, dial marking and the
terminals before using the meter. However, Fig
2 is for a particular make multimeter given for
your guidance. If you are using a multimeter for
the first time, it is always better to read the
instruction manual thoroughly atleast twice
before using the meter.

3 Set the function switch to DC position.

4 Set the range selector switch at the available higher
range of voltage in the multimeter.

If you are sure about the magnitude of the

voltage to be measured, then set the range
switch to the suitable range. Otherwise set the
multimeter range selector at a higher range.

86
5 Plug the black test lead in the common jack and the red 9 Observe the position of the pointer on the dial. If the
test lead in the positive jack. pointer deflects less than mid -scale, set the multimeter
range selector to the next lower range and so on, till
Some multimeters are provided with separate you get a reading just mid-scale or preferably beyond
female jacks for various measurements. Check mid-scale but within full scale.
and use proper jacks for D C.
Remember, if the percentage error is 3% for the
6 Connect the multimeter to the resistance board as full scale deflection at the middle of the scale,
shown in Fig 1. the error goes to 6% and for 1/4th scale
deflection the error shoots up to 12%. Hence it
Ascertain the supply polarity with respect to is advisable to get the reading somewhere
the meter polarity. between the centre of the scale to full scale to
have a lower error in the measurement.
7 Switch on the power supply.
8 Observe the pointer deflection of the meter. 10 Observe the selected voltage range and read the scale
of the meter and record them in Table 1 against the
If the needle deflects reverse, switch 'off' the column O-A.
voltage source and interchange the testing 11 Determine the multiplying factor and record it in
lead connections at the measuring points. Never Table 1.
disconnect the testing leads at the measuring
instruments. 12 Determine the actual value and record it in Table 1.

TABLE 1
DC voltage measurement

ed
bl I
Sl Measuring
pu M
Selected voltage Multiplication Measured Actual voltage

ish
No. points range factor (M.F) value (M.Value) M.Value x MF (volts)
Re NI
1 O-A
be @

2 O-B
o ht

3 O-C
t t rig

4 O-D
No py

5 O-E

6 O-F
Co

SPECIAL TASK : Common procedure for voltage and current measurements to read the multi-scale dial

i Ascertain the setting of the function switch to confirm

whether the quantity being measured is AC or DC.
(Refer to Fig 2).
ii Ascertain the setting of the range switch to confirm
whether the quantity being measured is voltage or
current and what is the suitable range.
iii Check the dial marking for the following as shown
in Fig 3.
a AC or DC scale as per setting of the function switch
b Voltage or current indication on scale as per setting
of the range switch.
c Range shown in dial and divisions as per setting
of the range switch.

Electronics & Hardware : Electronic Mechanic - Exercise 1.3.36 87

 iv From the setting of the range switch value (Step ii) and
the range shown in the dial(Step iii) determine the
multiplying factor.
v Ascertain the position of the pointer without parallax
error and read the number of divisions as shown by the
pointer on the scale.
vi Read the value, following the instructions given below.

If the pointer shows a reading within the scale, the

actual quantity of measurement can be calcu-
lated by considering the number of divisions
Sometimes the same scale will be used for two or shown by the pointer on the scale, setting of the
more measurements. Refer to Fig 3. 10V and range selector switch and the total number of full
1000V are having the same scale. 50V and 500V scale divisions as indicated in that range scale.
are having the same scale. 10 mA and 100 mA are
having the same scale. The quantity being meas-
ured is decided by the setting of the range switch.

The formula and the example given below will clarify this statement

Formula

ed
Actual quantity = Multiplying factor x No. of divisions shown by the pointer

bl I
pu M
ish
Setting of Range selector switch
Setting of range selector switch =
Re NI
Total divisions on the scale

Setting of Range selector switch x No. of divisions shown by the pointer

be @

Actual quantity =
Total divisions on the scale
Example - ( Figs 2 & 3)
o ht

1 Function switch -- DC position

t t rig

2 Range switch position voltage or current -- voltage

3 Range switch -- 2.5 V position
No py

4 Range shown in dial scale -- 250 V

Co

Setting of Range selector switch (step 3) 2.5 1

5 Multiplying factor= = =
Total divisions on the scale (step 4) 250 100

6 Read the number of divisions shown by the pointer (Fig 3) – 125.

7 Actual quantity = Multiplying factor x No. of divisions shown by the pointer
= (1/100)x125 = 1.25 volts.

13 Switch 'off ' the supply. 17 Follow the same procedure given in steps 13 to 16 for
measuring voltages between the points O-C, O-D,
14 Change the range selector switch to a suitable (next
O-E and O-F.
higher) range.
18 Show the readings to your instructor and get his
15 Connect the multimeter between the points O and B.
approval.
16 Read the voltage between the points O and B and
record in Table 1.

88 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.36

TASK 2 Measurement of AC voltage using a multimeter

1 Use the resistance board of Task 1 and connect the 5 Repeat the working steps 9 to 18 as in Task 1 and enter
same with AC supply as in Fig 2. the values in Table 2.
2 Set the function switch to AC position.

Remember that the multimeter function switch

should be set to match the type of source to be
measured.

3 Set the range selector at the highest range of AC

voltage.
4 Make connections to the multimeter and resistance
board as shown in Fig 4.

The polarity of the test leads is immaterial inAC

measurement. However make it a practice to
connect the common test prod (black) to the
near ground terminal and positive lead (red) to
the higher voltage terminal of the circuit.

TABLE 2
AC voltage measurement

ed
bl I
pu M
ish
Sl Measuring Selected voltage Multiplication Measured Actual voltage
No. points range factor (M.F) value (M.Value) M.Value x MF (volts)
Re NI
1 O-A
be @

2 O-B
o ht

3 O-C
t t rig

4 O-D
No py

5 O-E
Co

6 O-F

_______
TASK 3 Measurement of Direct current using a multimeter

1 Prepare the resistance board using the tag board with Before using the multimeter to measure the
resistors as shown in the circuit. (Fig 5). current, find out the DC ranges of the currents
2 Form the circuit with 12V DC supply as shown in Fig 5. to be measured and ensure that the circuit
current is well within the available range of
meter.

3 Set the function switch to the DC position.

4 Turn the selector switch to the highest range of cur-
rent, if the current to be measured is not known to you;
otherwise set to the known range.
5 Connect the test leads to the terminals of the multimeter
as indicated on the terminals or as shown in the
manual of that particular multimeter.

Now the multimeter is functioning as a DC

ammeter.

Electronics & Hardware : Electronic Mechanic - Exercise 1.3.36 89

6 Plug the multimeter between plug 1 and plug 2 in the
If the needle deflects less than half the scale,
circuit A to read the current in circuit A as shown in
set the multimeter range selector to the next
Fig 5.
lower range and so on, till you get a reading just
half scale or preferably beyond half scale but
Remember an ammeter should always be con-
within full scale.
nected in series with the circuit.
11 Observe the selected current range and determine the
7 Close the circuit switch for a moment and watch the
multiplying factor and record them in Table 3.
deflection of the pointer.
12 Compute the actual value and enter it in Table 3.
8 Open the switch immediately, if the pointer reaches
beyond the full scale deflection, reset the meter for a 13 Switch off the power supply.
higher range.
14 Change the multimeter connections to read the current
9 Switch off the supply, if the pointer shows a negative in the B circuit as shown in Fig 5.
direction of deflection and interchange the test leads at
15 Switch on the power supply and turn the selector
the measuring points.
switch to a suitable range so that the pointer reads
10 If the pointer shows the reading within the scale, keep within half and full scale positions.
the switch on, read the scale measurement and record
16 Read the scale of the multimeter and record in Table 3.
the readings in Table 3.
17 Repeat the procedural steps 11 and 12.
18 Repeat the above procedures for measuring the cur-
rent in the circuits C,D,E and F as in Fig 5.

ed
TABLE 3
DC current measurement

bl I
pu M
ish
Sl Measuring Selected current Multiplication Measured Actual current
Re NI
No. points range factor (M.F) value (M.Value) M.Value x MF (Amps)
be @

1 O-A
o ht

2 O-B
t t rig

3 O-C

4 O-D
No py

5 O-E
Co

6 O-F

-------------
TASK 4 Measurement of Alternating current using a multimeter
4 Make connections to the multimeter and resistance
Only certain types of multimeters will have the
board as shown in Fig 6.
facility of measuring alternating current. Check
whether the multimeter supplied to you has
Fig 6
this facility. If it does not have the facility, do
not attempt to measure alternating current by
your multimeter. If it has the facility, proceed as
stated below.

1 Prepare the resistance board using a tag board and

resistors as shown in Fig 6.
2 Set the function switch to the AC position.
3 Turn the selector switch to the highest current range
position.

90 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.36

5 Close the circuit switch for a moment and watch the 7 Follow the procedural steps given in steps 10 to 12 as
deflection of the pointer. in Task 3 with an exemption that the values should be
entered in Table 4.
6 Open the switch immediately if the pointer reaches
beyond the full scale.

TABLE 4
Alternating current measurement

Sl Measuring Selected current Multiplication Measured Actual current

No. points range factor (M.F) value (M.Value) M.Value x MF (Amps)

1 O-A

2 O-B

3 O-C

-------------

TASK 5 Measurement of resistance using a multimeter

1 Prepare the resistor boards using a tag board with

ed
Do not keep the ends shorted for a long time, to
resistors as shown in Fig 7.
avoid draining of the batteries. Before measuring

bl I
pu M the resistance of the resistor which is (inlaid) in

ish
the circuit, see that the power supply to the circuit
Re NI
is switched off. In the case of circuits having
electrolytic capacitors, they should be discharged
before attempting to measure resistance.
be @

7 Set the selector switch to a suitable resistance range

o ht

position.
t t rig

For every change of range switch for resistance

measurement, the zero error should be corrected
by shorting the leads. Try to ascertain the
No py

approximate value of resistance from your

experience. If the value cannot be ascertained set
Co

the range to R x 100 and then change the range

switch to make the pointer to indicate just in the
middle of the scale or beyond.
2 Set the selector switch in the resistance position.
8 Connect the testing leads to terminal positions O and
3 Plug the black test lead in the common jack, and the A as shown in Fig 7.
red lead in the positive jack.
9 Note the reading on the ohm's scale and record it in
4 Short the ends of the two testing leads to check zero Table 5.
error in resistance mode.
10 Calculate the actual value of resistance taking into
5 Adjust the zero ohms control (zero adjustment knob) consideration the multiplying factor.
until the pointer indicates zero ohm.
Ex. If the meter reading is 4 when the range switch is
in R x 100 position then the
If the pointer cannot be adjusted to zero, the
battery must be replaced. resistance value = 4 x 100 = 400 ohms.
11 Repeat the steps from 8 to 10 for OB, OC and OD
6 Open the shorted ends of the prods.
position.

Electronics & Hardware : Electronic Mechanic - Exercise 1.3.36 91

 TABLE 5
Resistance measurement

Sl. Measurement Selected ohms range Meter reading (M R) Actual value

No. points (Ohms) M R x Range (Ohms)

1 O-A

2 O-B

3 O-C

4 O-D

-------------

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

92 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.36

Electronics & Hardware Exercise 1.3.37
Electronic Mechanic - Measuring Technique

Identify the different types of meter for measuring AC & DC parameters

Objectives : At the end of this exercise you shall be able to
• identify the type of instruments (AC/DC) and their function from the dial markings.

Requirements
Tools and Instrumentss • Multimeter - 1 No
• Multi-range voltmeter
• Voltmeter 0 - 300 V MC - 1 No
MC 0-75, 150, 300 & 600 V - 1 No
• Ammeter MI 0-15 A panel board type - 1 No
• Multi-range voltmeter
• Ammeter 0 - 5A MC - 1 No
MI 0-150, 300 and 600 V - 1 No
• Ohmmeter-shunt and series type - 1 each

PROCEDURE
TASK 1 : Identify the types of instruments (AC/DC) and their functions from the dial marking

1 Identify the instruments shown in Figs 1 & 2 of Table

1 for the type AC, DC or both - with reference to Chart

ed
1. Record your response in Table 1.

bl I
pu M
2 Identify the functions of instruments by referring to the

ish
symbol on the dial. (Figs 1 & 2).
Re NI
be @
o ht
t t rig
No py
Co

93
 TABLE 1

Instrument Symbol Type AC/DC Function

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

3 Identify the instruments shown in Figures 3 to 12 as a

single or multi-scale/multi-range instruments and the
functions. Record your response in Table 2.
Record the observation in Table 1.

94 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.37

 TABLE 2

Instrument Range:single Scale single Function V

or multi-range or multi-scale or A or ohms

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.3.37 95

 Instrument Range:single Scale single Function V
or multi-range or multi-scale or A or ohms

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

96 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.37

 Instrument Range:single Scale single Function V
or multi-range or multi-scale or A or ohms

ed
bl I
pu M
ish
Re NI
be @

10
o ht
t t rig
No py
Co

11

Electronics & Hardware : Electronic Mechanic - Exercise 1.3.37 97

 Instrument Range:single Scale single Function V
or multi-range or multi-scale or A or ohms

Figs 12

ed
bl I
pu M
ish
Re NI
be @

4 Identify the working position, accuracy (error of 5 Further identify the given instruments from the
indication), type and function of the instruments in laboratory and fill up the details in Table 3.
o ht

Figs 1 & 2 and record in Table 3.

The serial number of the instrument and other distinct
t t rig

marks should be entered under the ‘instrument’ column.

TABLE 3
No py

Instrument Type Function Accuracy Working position

Co

Symbol Description Symbol Description Symbol Description Symbol Description

Figure 1

Figure 2

Lab instrument

Lab instrument

Lab instrument

98 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.37

Electronics & Hardware Exercise 1.3.38
Electronic Mechanic - Measuring Technique

Identify the different controls on the CRO front Panel and Observe the function
of each control
Objectives: At the end of this exercise you shall be able to
• identify the different controls on the CRO front Panel
• observe the function of each front panel control.

Requirements
Tools and Instruments Materials / components
• Front panel marked CRO - 1 No Note: The data sheet can download from the internet
as your CRO type and mark the label.

PROCEDURE
TASK 1 : Identify the different controls on the CRO front panel

1 Pick the labelled CRO from the table.

ed
bl I
2 Check the availability of the front panel control

pu M
ish
identification shown in the Fig 1 and note down name
of the controls in Table I.
Re NI
be @

Fig 1
o ht
t t rig
No py
Co

_______

99
 Table I

Label No. Front Panel Controls Name

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

3 Get the work checked by the instructor

_______
100 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.38
TASK 2 : Observe the function of the each front panel control in CRO
1 Refer the related theory of CRO Ex .no and find out the
front panel controls functions and note down in
Table -II

Table II

S No. Front Control Name Function

1 Power on

2 Intensity

3 Focus

4 Time base

5 Time Base Variable

6 Hold Off

7 ⇔ Position / x5

8 Level

ed
bl I
9 Auto / Norm

pu M
ish
10 Int/ Ext
Re NI
11 Line
be @

12 TV
o ht

13 +/-
t t rig

14 CH1/CH2
No py

15 HF Rej

16 ac / dc
Co

17 SWP / X-Y

18 0.2, 1KHz

19 Positions Ú

20 AC/DC/ Gnd

21 EXT / TRIG

22 INPUT BNC CH1/Y (CH2/X)

23 TRACE

24 CH1/CH2 ATTENUATOR

25 VERTICAL MODES

a. ALT/CHOP

Electronics & Hardware : Electronic Mechanic - Exercise 1.3.38 101

 Front Control Name Function

b. DUAL /MONO (X-Y)

c. CHANNEL ADDTION (CH1 - CH2)

d. CHANNEL SUBTRACTION (CHI-CH2)

e. CH2 INV

2 Get the work checked by the Instructor.

_______

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

102 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.38

Electronics & Hardware Exercise 1.3.39
Electronic Mechanic - Measuring Technique

Measure VDC, VAC, time period using CRO sine wave Parameters
Objectives : At the end of this exercise you shall be able to
• identify the controls of cathode ray oscilloscope
• measure D.C. voltage (VDC)
• measure the P.P. values of AC voltage (VP-P)
• measure the time period of a sine wave parameters.

Requirements
Equipment/Machines Materials
• DC power supply 0- 30 V, 1 A - 1 No • Probes for oscilloscope - 1 set
• 5 MHz oscilloscope single beam type - 1 No • Dry cell 1.5 V - 1 No
• Transformer 240/12 V 200 mA - 1 No

PROCEDURE
TASK 1 : To identify the respective functions and adjustments of switches and knobs in an oscilloscope

ed
1 Observe the front panel of the CRO which may look 4 Set the switches and controls as indicated below

bl I
similar to the diagram in Fig 1.
Intensity - off
pu M
ish
Time - 10m sec/ division
Re NI
Horizontal position - centre
Attenuator (V/Div) -5V
Focus - centre
be @

T.B. vernier - cal position

Vertical position - centre
o ht

AC-DC switch - DC (push in) position

Trigger mode - Auto
t t rig

Trigger source - Int

5 To get a raster line turn on the power intensity switch
No py

about 3/4 turn. A trace will appear after a few seconds.

6 Adjust the horizontal and vertical controls to centre the trace
Co

and focus, intensity controls for a sharp bright trace.

7 Plug the black (ground) prod into the common terminal

with the earth link in position between the common and
2 Check that the power switch of the oscilloscope is in off ground terminal. Next plug the red (signal) prod into
position. the input terminal.
3 Connect the power chord of the CRO to the AC power
outlet.
_______

TASK 2 : Measurement of D.C. voltage

1 To measure the voltage of the Dry cell, set the attenuator 3 Observe the trace on the screen. It will be observed
to 0.5 V / div. that the trace will move up by 3 divisions from the
centre line indicating the voltage is positive.
2 Connect the black (ground) prod to the negative end
and the red prod to the positive end of the dry cell as The magnitude of the emf of the cell is given by 3 div
shown in Fig 2. x 0.5 V/Div = + 1.5 volts.

103
4 Now reverse the leads, the trace will move down by 3
divisions indicating the voltage is negative and again
the emf of the cell = 3 x 0.5 = -1.5 V.
5 Set the attenuator to 5V/Div.
6 Instead of a dry cell use the regulated DC power supply
(0-30V) and repeat steps 2 to 4 and record the obser-
vations in Table 1.

TABLE 1

Trial No Power Supply Attenuator No. of Divisions No. of Divisions Voltage measured
voltage in volts position moved up moved down in CRO

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

_______

TASK 3 : Measurement of AC voltage

1 To measure AC voltages, set the AC-DC switch in

(out) AC position.
2 Set the attenuator (volts/div) to 50 V if the input volts is
unknown and adjust the time base switch to 10 milli
second.
3 Connect the isolation transformer secondary leads
one to the common input terminal to the ground side
for signal source and another lead to the input terminal
as shown in Fig 3.
4 Switch on the oscilloscope, adjust the trace to center
and focus intensity controls for a sharp bright trace.
5 Switch on and energise the primary of the transformer
as shown in circuit in Fig 3.

104 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.39

6 Observe the wave form that appears on the screen. 9 To determine the RMS value of the voltage, divide the
P-P voltage by 2.83 (2 x 2). Enter the value in
7 Increase the vertical sensitivity by the volts/div switch
Table 2.
such that the wave form display is clearly seen.
8 Measure the peak to peak voltage of the displayed
wave form, by counting the number of divisions be-
tween positive and negative peaks. Record the obser-
vations in Table (2) for example - if the no. of divisions
counted is 6 when attenuator is set to 5V then the
amplitude is 6 x 5 = 30 volts P-P.

TABLE 2

Trail No. Attenuator switch No. of divisions counted Peak to Peak RMS voltge
range volts / Div peak to peak voltage

1 2 3 4 5

ed
bl I
pu M
ish
Re NI
be @

_______
o ht
t t rig

TASK 4 : Measurement of time period of a sine wave

No py

1 After measurement of P-P voltage in Task 3, turn the 3 Count the no. of divisions horizontally for one complete
time base vernier (1) (refer Fig 1) to cal position. cycle and record the same in tabular column (3).
Co

Example if a complete cycle is 2 divisions long as

2 Set the time/ div switch to a range where the signal can
shown in Fig 3 when the time base switch range is 10
be clearly seen.
millisec then the time period for the wave form is
2 x 10 = 20 ms.
Formula to be used
Time period t = Time base range x No. of divisions / cycle.

Electronics & Hardware : Electronic Mechanic - Exercise 1.3.39 105

 TABLE 3
Trail No. Attenuator switch Timebase range No.of Divisions Time period
position volts / Div milli sec per cycle

ed
bl I
pu M
ish
_______
Re NI
be @
o ht
t t rig
No py
Co

106 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.39

Electronics & Hardware Exercise 1.3.40
Electronic Mechanic - Measuring Technique

Identify the different controls on the function generator front panel and observe
the function of each controls
Objectives: At the end of this exercise you shall be able to
• identify the different front panel control in function generator
• identify the different rear panel connectors available in function generator
• observe the function of each front panel control in function generator.

Requirements
Tools / Equipments/ Instruments Materials / Components
• Front panel marked Digital Note: The data sheet can download from the internet as
Function Generator - 1 No your digital Function Generator Type and mark the label.

PROCEDURE
TASK 1 : Identify the different controls on the Function generator front Panel

ed
1 Pick the labelled Function Generator from the table.
1

bl I
pu M
2 Check the availability of the front panel control

ish
identification shown in the Fig 1 and note down name
Re NI
of the controls in Table I.
3 Get the work checked by the Instructor.
be @
o ht
t t rig
No py

Table - I
Co

Label No. Front PanelControls Name

10

107
 Label No. Front PanelControls Name

11

12

13

14

15

16

17

18

19

20

ed
21

bl I
pu M
ish
22
Re NI
23
be @

24
o ht

25
t t rig

26
No py
Co

_______

TASK 2 : Identify the different rear panel connectors available in function generator

1 Pick the labelled Function Generator from the table. 2

2 Check the availability of the front panel control
identification shown in the Fig 2 and note down
name of the controls in Table II.
3 Get the work checked by the Instructor.

108 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.40

 Table - II

Label No. Rear panel connectors name

ed
10

bl I
pu M
ish
11
Re NI
12
be @

13
o ht

14
t t rig
No py

_______
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.3.40 109

TASK 3 : Observe the function of the each front panel control in function generator

1 Refer the related theory of Function Generator Ex

no and find out the front panel controls functions
and note down in Table -III
2 Get the work checkd by the Instructor.

Table-III

S No. Front Control Name Function

1 POWER ON

2 USB host

3 Mode Key

4 Menu Keys

5 Sine Wave

ed
6 Square wave

bl I
pu M
ish
7 Ramp wave
Re NI
8 Pulse wave
be @

9 Noise wae
o ht

10 Number keys
t t rig

11 Trigger control
No py

12 Output control
Co

13 Knob

14 Display

15 Direction Keys

16 Mode / function

17 Sys Output

18 Sweep

19 Burst

20 Utility
_______
110 Electronics & Hardware : Electronic Mechanic - Exercise 1.3.40
Electronics & Hardware Exercise 1.4.41
Electronic Mechanic - Soldering & Desoldering

Practice soldering on different electronic components, small transformer and

lugs
Objectives : At the end of this exercise you shall be able to
• Solder lugs
• Solder different electronic components
• Solder a small transformer.

Requirements
Material/Components Tools/Equipment/Instruments
• Lug board (Code No.103-06-LB) • Soldering iron 60w - 1 No
• Single strand wire(hook-up-wire) - 1 meter • Trainees kit - 1 No
• Solder - 25 gms • Cleaning brush, 1/2inch - 1 No
• Soldering flux - as reqd • Mini transformer - 1 No
• Eletrician knife - 1 No
• Electronic components as available - as reqd
Note:

ed
1 Use any lug board from market.but similar to that
shown in fig 5,

bl I
pu M 2 The cleaning brush shall be retained by the trainees

ish
as a part of trainees tool kit
Re NI
PROCEDURE
be @

1 Keep ready the soldering iron for soldering. 5 Repeat steps 3 and 4 and tin all the lugs on the lug
board. Get the tinned lugs checked by the instructor
o ht

2 Check if the lugs of the lug board are bright/already

tinned. If not, scrap the outer face of lugs,using 6 Skin one end of given single strand wire to a length of
t t rig

knife such that,the oxide layer/varnish is removed. 1cm. Tin the exposed conductor.
Wipe the lugs with a piece of dry cloth.
7 Insert and bend the tinned wire in lug 1 hole as
No py

3 Apply a thin layer of flux on the outer face of the lug shown in Fig 2. (side entry method)
as shown in Fig 1a.
Co

8 As shown in Fig 3a, hold the bit of the soldering iron

4 To tin the lug, hold the bit of soldering iron at the on the inner face of the lug without touching the wire
inner face of lug no.1 and wait for 1 to 2 seconds. for 1 to 2 seconds.Apply solder at the outer face of
Hold the tip of solder wire at the outer face of the the lug as shown in Fig 3b. Once the solder melts
lug as shown in Fig 1b. As the solder melts and and flows over the tinned wire and lug as in Fig 3c,
flows on the lug, take out the solder wire and iron take away the iron and solder from lug.
from the lug.
Refer Fig 5 lug numbers. Note: Allow the solder joint to cool naturally.
If the joint is cooled by blowing air, the joint
Allow a very small quantity of solder to flow over the lug. will become a dry solder joint and, hence,
will be a wear shaking of wire/lug board
Do not shake the board till the melted solder before cooling, results in dry solder joint.
dries up by itself.
Do not blow air to cool the solder on the lug.
111
 11 Skin the wire for 10mm using a wire stripper and tin
the skinned end.
12 Insert the tinned wire end into the hole of lug11, bend
the wire as done in step 8. Solder the wire as done at
step 9.
13 Follow steps 7 to 12 above to solder and bend the
wire to obtain a wiring as close as possible to that
shown in Fig 5.

9 Get the soldered joint checked by the instructor.

10 Take the wire along the path from, lug 1 to lug 11 as
shown in Fig 4. Cut the wire at a point 10mm a head 14 Clean the soldered points using a brush to remove
of lug 11. excess flux.

ed
Use flat nose plier to lay the wire. NOTE : Excess of flux may corrode the lugs.

bl I
pu M
ish
15 Get your work checked by the instructor.
Re NI
16 Solder different electronic components and small
transformer similarly by following the steps 3 to 8.
be @

17 Get the soldered joint checked by the instructor.

o ht

NOTE: Do not desolder/remove the soldered

wire. This will be done as a separate exercise.
t t rig
No py
Co

_______

112 Electronics & Hardware : Electronic Mechanic - Exercise 1.4.41

Electronics & Hardware Exercise 1.4.42
Electronic Mechanic - Soldering & Desoldering

Practice soldering on IC bases and PCBs

Objectives: At the end of this exercise you shall be able to
• Soldering on the IC bases
• Soldering on the PCBs.

Requirements
Tools / Equipments Materials
• Soldering Iron, 25W - 1 No • General Purpose PCBs (GP board - 1 No
• Trainees tool kit - 1 Set • IC base (4 pin or 8 pin) - 1 No
• Soldering stand - 1 No • Soldering Wire - as reqd
• Flux - as reqd
• Soldering Wick - as reqd
• Soldering tip clear sponge - as reqd

PROCEDURE

ed
1 Clean the tip as shown in the Fig 1.
3

bl I
pu M
ish
1
Re NI
be @
o ht
t t rig
No py

4
2 Tinning the tip as shown in Fig 2.
Co

3 View the front and back view of general purpose PCB

as shown in Fig 3.
4 Get work checked by the instructor.
5 Fix the GP Board on stand as shown in Fig 4.
6 Check the IC base all the pins in correct shape as
shown in Fig 5.

113
7 If any pin damage replace with another IC base. 10 Turn the GP board to back side and solder the IC base
as shown in Fig 8.
8 Find the first pin of the IC base as shown in Fig 6.

8
6

11 Get work checked by the instructor.

9 Insert the IC base in GP board front side as shown in
the Fig 7.

ed
bl I
pu M
ish
Re NI
be @
o ht

_______
t t rig
No py
Co

114 Electronics & Hardware : Electronic Mechanic - Exercise 1.4.42

Electronics & Hardware Exercise 1.4.43
Electronic Mechanic - Soldering & Desoldering

Practice de-soldering using pump and wick

Objectives : At the end of this exercise you shall be able to
• De-soldering using de-solder pump
• De-soldering using solder wick.

Requirements
Tools and Instruments Materials
• Soldering iron, 25W - 1 No • De-solder wick - as reqd
• Trainees tool kit - 1 No • Cleaning solution - as reqd
• De-solder pump - 1 No • Flux - as reqd
• Tooth Brush - 1 No
• Safety goggles - 1 No
• Safety gloves - 1 No
• De-soldering PCB board - as reqd

PROCEDURE

ed
TASK 1 : De-soldering using de-solder pump method

bl I
pu M
ish
1 Locate the de-soldering component to be removed in 4 Clean the soldering iron tip as shown in Fig 3.
Re NI
PCB as shown in Fig 1.
3
be @

1
o ht
t t rig
No py
Co

5 Push down on the de-soldering pump (refer the related

2 Clean the terminals as shown in Fig 2. theory) as shown in Fig 4.
2 4

3 Attach the heat sink with help of the instructor.

6 Use the solder iron to heat the desolder pad as shown
Note: Heat sink is used for avoiding the more in Fig 5.
heat of iron and avoid other component damage.

115
 9 Apply the flux on the soldered pad as shown in Fig 8.
5

7 Touch the tip of the de-soldering pump to the solder

pad and melted solder, without applying pressure as
shown in Fig 6. 10 Clean the board as shown in Fig 9.

9
6

ed
bl I
pu M
ish
Re NI
8 Empty the de-soldering pump into the trash as shown 11 Get work checked by the instructor.
be @

in Fig 7.
o ht

7
t t rig
No py
Co

_______

116 Electronics & Hardware : Electronic Mechanic - Exercise 1.4.43

TASK 2 : De-soldering using de-solder wick

1 Follow the steps 1 to step 6 in Table I.

3
2 Unwind few inches of board from the coil as shown in
Fig 1.

5 Place a hot soldering iron against the braid and desired

pin as shown in Fig 4.

3 If your solder wick does not have flux on it, it would be

a good idea to add flux to the section you are going to
use and make for a clean removal as shown in Fig 2.

ed
2

bl I
pu M
ish
Re NI
be @

6 Remove the braid. The braid will be very hot at this

point, so make sure not to touch the braid itself, only
the spool.
o ht

7 Remove the solder wick along with the heat.

t t rig

8 Allow to solidify within the wick apart from the work

4 Place the braid over the joint you want to rework as piece.
No py

shown in Fig 3.
9 Discard the used section of wick.
Co

10 Get work checked by the instructor.

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.4.43 117

Electronics & Hardware Exercise 1.4.44
Electronic Mechanic - Soldering & Desoldering

Join the broken PCB track and test

Objectives : At the end of this exercise you shall be able to
• repair the broken PCB track and test.

Requirements
Tools / Equipment / Instruments Materials /Components
• Trainees tools kit - 1 Set • Broken PCB - 1 No
• Soldering iron 25 watts - 1 No • Epoxy tube - 1 No
• Knife - 1 No • Emery cloth /paper - as reqd
• Tweezer - 1 No • Magnifying glass - 1 No
• Multimeter with probe - 1 No • Solder flux, resin core, solder Cleaning
solvent (IPA), Sponge - as reqd
• Tooth brush - 1 No

PROCEDURE
1 Identify the broken track on PCB using magnifying 7 Clean the hot soldering tip by wiping it on a wet sponge.

ed
glass as shown in Fig 1.

bl I
Make sure that all the dirt and oxidation re-
pu M
ish
1 moved from the tip.
Re NI
8 Apply a fresh “tinning “ coat on the soldering tip as
shown in Fig 2.
be @

2
o ht
t t rig
No py
Co

2 Mix the Epoxy according to the manufacturer’s

instructions and apply it sparingly to one side of the
PCB.
3 Press the two halves of the broken PCB together and
hold them until the epoxy takes hold. A properly tinned tip will be a bright silvery
colour. If the tip is a dull gray colour, you need
The epoxy will set in a few seconds, but you to repeat steps 7 and 8. Until you achieve a
should wait for thirty minutes before proceeding properly tinned tip. This is necessary for the
to next step. efficient transfer of heat during the soldering
process.
4 Cut through the broken copper traces using a razor
knife. 9 Apply resin - core solder to the bare copper traces on
5 Remove all loose traces and use emery sheet to sand the PCB Fig 3.
the traces.
Apply sufficient heat to melt the solder. Too
Sand the ends of these traces until bright copper much heat will cause the copper traces to sepa-
shows clearly. rate from the board.

6 Plug the soldering iron into socket outlet and wait for 10 Cut a long piece of 18 gauge copper wire to span cut
a while to get hot. trace and tin these short lengths of wire with resin core
solder.

118
 11 Pick up a piece of tinned wire with the tweezers and
3
place it carefully across one of the traces where you
removed a loose section.
12 Touch the soldering pencil’s tip to the top of wire lying
across the gap until it fuses to copper trace on the
board.
13 Repeat this steps for the remaining wires.
14 Reassemble the device and test it to see if it works
properly.
15 Get your work checked by the instructor.

_______

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.4.44 119

Electronics & Hardware Exercise 1.4.45
Electronic Mechanic - Soldering & Desoldering

Identify and use SPST, SPDT, DPST DPDT,tumbler. push button, toggle , piano
switches used in electronic industries
Objectives : At the end of this exercise you shall be able to
• identify SPST, SPDT, DPST, DPDT TUMBLER, push button toggle and piano switches
• test all above switches.

Requirements

Tools / Instruments Materials /Componets

• Trainess Tool Kit - 1 set • SPST switch 6A,240V - 1 No
• Multimeter - 1 No • SPDT Switch 15A, 240V - 1 No
• DPST Switch 15A, 240V - 1 No
• DPDT Switch 15A,240V - 1 No
• Tumbler switch, 1 pole, 16A, 240V - 1 No
• Push button switch 6A, 240V - 1 No
• Toggle Switch - 1 No
• Piano Switch 6A, 240v - 1 No

ed
bl I
PROCEDURE
pu M
ish
The instructor shall arrange different types of Assumption : A set of switches mentioned in
Re NI
switches collected from store for identification this exercise are to be displayed on the work
and uses of switches. bench. Trainees are required to identify the
be @

switches and draw the sketch in the allotted

1 Identify different types of switches by physical column.
o ht

appearance and draw its sketch in the Table 1.

2 Test the switches by operating (ON/OFF mode) and
note down in Table 1.
t t rig

3 Get your work checked by the instructor.

No py

Table I
Co

S.No Name of Switch Sketch Continuity Test

On Mode off-Mode

(1) SPST

(2) SPDT

(3) DPST

(4) DPDT

(5) Tumbler

(6) Push button

(7) Toggle

(8) Piano

120
 1 SPST 2 SPDT

3 DPST DPDT
4

ed
bl I
pu M
ish
Tumbler 6 Push button
5
Re NI
be @
o ht
t t rig
No py
Co

Fig 7 Toggle Switch Fig 8 Piano Switch

Electronics & Hardware : Electronic Mechanic - Exercise 1.4.45 121

Electronics & Hardware Exercise 1.4.46
Electronic Mechanic - Soldering & Desoldering

Make a panel board using different types of switches for a given application
Objectives : At the end of this exercise you shall be able to
• draw a schematic diagram to show one electric bell controlled by one push button switch on the panel board.
• fix different types of switches on the panel board
• wire the cable on the panel board according to the wiring diagram
• connect the cables in the accessories
• test the circuit.

Requirements
Tools / Instruments Materials
• Screw driver 150mm - 1 Set • Wooden Panel Board available
• Cutting pliers 200 mm - 1 No in the section - 1 No
• Hand drilling machine with 3mm/ • Bell push switch 6A,240V
4 mm drill bit each one - 1 No (Surface Mounting) - 1 No
• Electrician Knife - 1 No • Electric bell 240V - 1 No
• Side cutting plier - 1 No • Wood Screws - as reqd
• Trainees tool kit - 1 Set • SPST - 1 No

ed
• Try square 150mm - 1 No • SPDT - 1 No

bl I
• Poker 200 mm - 1 No • DPST - 1 No

pu M
ish
• Tumbler switch - 1 No
• Toggle switch - 1 No
Re NI
• Piano switch - 1 No
be @

PROCEDURE
o ht

1 Draw the layout diagram as shown in Fig 1.

t t rig
No py
Co

2 Collect the calling bell, SPST, SPDT, DPST, DPDT, 8 Get it checked by the instructor.
tumbler switch, bell push switch, toggle switch and
piano switch. If it is incorrect make necessary changes.
3 Place the switches and calling bell on the panel
board to suit the technical aspects. 9 After getting the approval of the instructor connect
the main supply and test the circuit.
4 Mark the position of switches on the panel board as
per the given layout. 10 Connect other switches for different applications
and get the formed circuit checked by instructor.
5 Fix the switches and calling bell on the panel board.
6 Prepare the end termination of the cables. Insert
them into respective switches.
7 Give connections to Bell Push switch and Electric
bell as per connection diagram mentioned in Fig 2
and test it.

122
Electronics & Hardware Exercise 1.5.47
Electronic Mechanic - Active and Passive components

Identify the different types of Active electronics components

Objectives : At the end of this exercise you shall be able to
• identify the different types of active electronics components by referring to the pictorial representation..
• identify the different types of active electronics components by referring to label names.

Requirements
Tools/Equipments/Instruments • ICs (Integrated Circuits) - 1 No
• UJT (Unijunction Transistor - 1 No
• ESD table - 1 Set
• FET (Filed Effect Transistor ) - 1 No
• ESD Gloves - 1 Set
• DIAC - 1 No
• Magnifier lens - 1 No
• TRIAC - 1 No
Materials / components • SCR (Silicon-Controlled Rectifier) - 1 No
• Bridge diode - 1 No
• Diode - 1 No
• All the Components Data sheet - 1 No
• Zener diode - 1 No
• Transistor /BJT (Bipolar
Junction Transistor) - 1 No

ed
bl I
Note: The data sheet can download from the
pu M
ish
internet as per your components manufacture.
Re NI
PROCEDURE
TASK 1: Identify the different types of Active electronics components by referring to the pictorial representation
be @

Assumption : Given components have their

o ht

b
code Number, Lead identification marks as
well as related data sheets are available.
t t rig

1 Look at the Fig 1 identify the component name from the

No py

pictorial representation (shape, leads, colors).

Co

123
 d e

f g

ed
bl I
pu M i

ish
h
Re NI
be @
o ht
t t rig
No py

j
Co

124 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.47

2 Record the names of components in tabel I
Table- I

Sl.No Figure No. Active components Name

1 A

2 B

3 C

4 D

5 E

6 F

7 G

8 H

9 I

10 J

ed
bl I
pu M
ish
3 Get the work checked by the Instructor
Re NI
_______
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.5.47 125

Electronics & Hardware Exercise 1.5.48
Electronic Mechanic - Active and Passive components

Measure the resistor value by colour code and verify the same by measuring
with Multi meter
Objectives : At the end of this exercise you shall be able to
• measuring the resistor value by colour code
• measuring the resistor value by multi meter.

Requirements
Tools/Equipments/Instruments Materials/components
• Digital Multi meter with Probe - 1 No • Assorted types & fixed value colour
code resistors
(4 band, 5 band, 6 band) - Each 5 nos
• Bread Board - 1 No
• Crocodile teeth connector - 1 Set

PROCEDURE
TASK 1: Measure the Resistor value using Colour code

ed
bl I
1 Take a colour coded resistor from the given lot.
pu M 1A. 6 Band Resistor

ish
2 Check the resistor colour codes find the type of
Re NI
band resistor and note down in the Table - I
3 Identify the colors of bands starting from one end of
be @

the resistor as shown in Fig 1A.

4 To read the colour code from small band Gap and
o ht

note down the table I.

5 Refer the Colour Code Chart as shown in Fig 2.
t t rig

6 Record the values in Table I

No py

7 Calculate the value of the resistor (see the ex-

ample)
Co

2A. 5 Band Resistor

Example: Yellow, Violet Red Gold = 472 = 47 x

100 = 4700 Ω or 4κ7±5%
8 Get the work checked by the Instructor.

126
 3A. 4 Band Resistor 2

Table - I

S No. Band Colour Colour Colour Colour Percentage Temperature Value of

Type of 1st of 2nd of 3rd of 4th Band Tolerance Coefficient Resistors
Band Band Band (Multiply) %

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py

_______
Co

TASK 2 : Measure the resistor value by multi meter

1 Take a colour coded Resistor from the given lot . 4 Plug the red probe into the VΩ mA port as shown in
2 Place the Resistor in the Table. Fig 2.

3 Plug the black probe into the COM port on your

2
multimeter as shown in Fig 1.

Electronics & Hardware : Electronic Mechanic - Exercise 1.5.48 127

5 Turn the multimeter knob to the W Resistor/continu- 9 Place the multimeter probes on two sides of resis-
ity mode as show in Fig 3. tors as shown in Fig 5.

3 5

6 Turn on the multimeter.

10 See the multimeter display note down the value of
7 Select the required range of the resisting in multim- the resistor in Table II.
eter.
11 Get the work checked by the Instructor.
8 Insert the resistor in bread board as shown in Fig 4.
12 Place the resistor on the table place the probe on the
two sides of the resistor as shown in Fig 6.
4

ed
bl I
pu M
ish
Re NI
be @
o ht

13 See the multimeter display note down the value of the

t t rig

resistor in Table II.

No py

Table - II
Co

S No. Resister Value Ω

14 Get the work checked by the Instructor.

_______

128 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.48

Electronics & Hardware Exercise 1.5.49
Electronic Mechanic - Active and Passive components

Identify resistors by their appearance and check Physical defects

Objectives : At the end of this exercise you shall be able to
• identify different types of fixed value resistors by their appearance
• check the physical condition of fixed resistors.

Requirements
Materials/Components
• Assorted types & values of fixed
value resistors - 20 Nos

PROCEDURE
TASK 1 : Identify different types of resistors

1 Take a resistors from the given lot and observe its 6 For the same resistor, refer Chart 2 and check for
physical appearance. Identify type name and record physical damages, if any, on the body of the resistor.
it in Table 1. Record the identified defect code.

ed
2 Observe physical size of each resistor, get the help of 7 For the same resistor, check for clear visibility of colour

bl I
pu M
instructor to know wattage rating of each size. bands or printed resistor value on the body of the

ish
resistor. Tick the appropriate statement in Chart 1.
3 Repeat step 1&2 for the remaining given resistors.
Re NI
8 From the conditions of the resistor noted in Chart 2.
4 Get the work checked by the instructor.
give your conclusion about the usability of this resistor
be @

5 Take a resistor and check for lead damages if any

9 Repeat steps 4 to 7 for the remaining resistors and get
record the identified lead defect code in chart - 1.
your work checked by the instructor.
o ht

Table - 1
t t rig

Resistor's Type name Lead Physical Resistor value Overall usability

No py

label No. defect code defect code visibility of resistor

Co

Sample Ceramic LS/LW/SL SPE/BCH/ Visible Fit/ unfit

entry with BCR/CSH Not visible
Axial leads

Visible

Not visible

Visible

Not visible

Visible

Not visible

Visible

Not visible

129
 CHART 1

LEAD DEFECTS DEFECT REMARKS USABILITY

CODE

Shake at NECK JOINT LS May become

electrically open,
(Lead Shakey) while handling, UNFIT
bending.

Lead with WEAK POINTS LW Lead may get

cut while
(Lead Weak) handling, UNFIT
Bending.

ed
bl I
pu M
ish
Strong NECK JOINT & SL
Re NI
no WEAK POINTS (Strong Leads)
----- FIT
be @
o ht
t t rig
No py
Co

CHART 2

PHYSICAL DEFECT DEFECT CODE REMARKS USABILITY

Skin coating peeled off SPE Value might have deviated UNFIT

Body cracked BCR May be open or value deviated UNFIT

CAP Shacking /cracked CSH May be open or loose contact UNFIT

Body charred or BCH May be open, short, UNFIT

become blackish value deviated

_______

130 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.49

Electronics & Hardware Exercise 1.5.50
Electronic Mechanic - Active and Passive components

Identify the power rating of carbon resistors by their size

Objectives : At the end of this exercise you shall be able to
• identify the power rating of carbon resistors.

Requirements
Materials/Components
• Carbon resistors - as reqd
• Trainees tools kit - 1 set

PROCEDURE
Note: A set up different types sizes and ratings 2 Measure the sizes of carbon resistors.
of carbon resistors as shown in the figure to be 3 Note down the power rating of carbon resistors.
displayed on the work bench.
4 Write your above findings in the Table.
1 Identify the types of carbon resistors.

ed
bl I
Table
pu M
ish
Carbon Resistors
Re NI
S No. Type Size Power Rating in Watt Remarks
be @
o ht
t t rig
No py
Co

131
 6

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig

4
No py
Co

132 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.50

Electronics & Hardware Exercise 1.5.51
Electronic Mechanic - Active and Passive components

Practice on measurement of parameters in combinational electrical circuit by

applying ohm’s law for different resistor values and voltage sources
Objectives: At the end of this exercise you shall be able to
• verify the characteristics of series and parallel combinational circuits.

Requirements
Tools / Instruments Equipments / Materials
• Electrician tool kit - 1 Set • DC 0-150V Variable voltage supply
• MC Ammeter 0 -1A - 3 Nos source with current limiting
• MC Voltmeter 0-150V - 1 No facility 0-1A - 1 No
• MC Voltmeter 0-100 V - 3 Nos
Materials
• Rheostat 25 Ohms 1A - 1 No
• Rheostat 40 Ohms 1A - 1 No • SPT switch 6A,250V - 1 No
• Rheostat 60 Ohms 1A - 1 No • Connecting cables - as reqd
• Rheostat 300 Ohms 1A - 1 No
• Multimeter as available - 1 No

ed
bl I
PROCEDURE
pu M
ish
TASK 1 : Verify the characteristics of series and parallel combinational circuits.
Re NI
1 Form the circuit as shown in Fig 1. 3 Calculate the total resistance RT and total current
be @

IS for Vs=50V and enter in Table - I.

4 Set the value of the rheostat resistance equal to the
o ht

value given in Fig 1 (ie., R1 = 25Ω , R2 = 300Ω , R3=

40Ω, R4= 60Ω by measuring the resistance value
t t rig

between one end and the variable point of the rheostat)

5 Close the switch ‘S’ measure the current and voltage
No py

record them in the Table - I.

Co

6 Calculate the value of RT from VS and IS and enter

in Table - 1 compare with the value obtained in step-
5 and enter in Table - 2.
7 By applying 100V as VS with some value of resistors
as in Fig. Calculate the value of RT from VS and IS and
enter in Table 3.
8 Enter the calculated and measured values in Table 4
for comparision.
2 Calculate the voltage and current in each resistor
of the series parallel combinational circuit shown in
Fig 1 and enter the values in Table - 1

133
 Table-1

VRI IS I2 VR2 I3 VR3 R3+R4 R2 || (R3+R4)

VS = 50VΩ
Calculated Values
R1 = 25Ω

R2 = 300Ω

R3 = 40Ω
Measured Values
R4 = 60Ω

Table-2

Calculated RT = R1 + {R2 || (R3+R4)} =

ed
Measured Vs
RT = =

bl I
pu M Is

ish
Re NI
be @

Table-3

R2 ||
o ht

VRI IS I2 VR2 I3 VR3 R3+R4 (R3+R4)

t t rig

VS = 50VΩ
No py

Calculated Values
R1 = 25Ω
Co

R2 = 300Ω

R3 = 40Ω
Measured Values
R4 = 60Ω

Table-4

Calculated RT = R1 + {R2 || (R3+R4)} =

Measured Vs
RT = =
Is

134 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.51

Electronics & Hardware Exercise 1.5.52
Electronic Mechanic - Active and Passive components

Verify measurement of current and voltage in electrical circuits to Kirchhoff’s

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

Requirements
Tools/Instruments/Equipment Materials
• Trainees kit - 1 No • Resistors 1K - 4 Nos
• Variable DC power supply • Resistor 2.2K - 1 No
unit 0-30V/1A - 2 Nos • Resistor 3.3K - 1 No
• Milliammeters 0 - 10 mA - 3 Nos • Resistor 4.7K - 1 No
• Milliammeters 0 - 30 mA - 1 No • Lug board - 1 No
• Toggle switch, SPST ,1amp - 2 Nos
• Patch cords - as reqd

ed
bl I
pu M
ish
PROCEDURE
Re NI
TASK 1 : Verify the Kirchhoff’s Current Law with two branch currents
be @

1 Connect the PSU, milliammeters, SPST switch and

resistors as illustrated in the circuit schematic and the
o ht

layout diagram as shown in Fig 1.

Keep the SPST and PSU in the OFF position

t t rig

while making circuit connections.

No py

2 Switch ‘ON’ PSU and set output to 12 volts.

Co

3 Simplify the circuit at Fig 1 and calculate the theoretical

total circuit current and branch currents of the circuit
for a set dc supply of 12 volts. Record values in
Table 1.

Check the ammeters connected are suitable to

measure the calculated current. Change the
meter if necessary.

4 Get the circuit connections checked by your instructor.

5 Switch ON SPST.
6 Measure and record the total circuit current (IT) and
branch currents IB1 and IB2 in Table 1.
7 Switch OFF the SPST.
8 Set the output of the RPSU to 9 volts.
9 Calculate the theoretical circuit currents for the set
supply voltage of 9V.
10 Record values in Table 1.
11 Repeat steps 4 & 6.

135
12 Switch OFF SPST and PSU. 14 Verify the equation substituting measured current
values.
13 Write Kirchhoff’s current equations for the nodes P
and Q.
TABLE 1

Calculated values of circuit current Measured values of circuit currents

Set circuit
voltage
Total circuit IB1 IB2 Total circuit IB1 IB2
current current

12 V

9V

15 Get the readings and equations checked by the

instructor.
_______

TASK 2 : Verify the Kirchhoff’s Curent law with three branch currents

ed
bl I
1 Make circuit connections on the lug board as per the
Make it a practice to keep the SPST and PSU
pu M
ish
schematic in Fig 2.
switches in the OFF position while making
circuit connections.
Re NI
2 Get the wired circuit checked by the instructor.
be @

3 With the SPST in OFF position, set the output of PSU

to 12 volts.
o ht

4 Switch ON the SPST switch. Measure and record

t t rig

currents IT, IB1, IB2 and IB3 in Table 2.

5 Switch OFF SPST and PSU.
No py

6 Write Kirchhoff’s current equations at nodes P and Q.

Verify the equation using measured current values.
Co

7 Get the readings and equations checked by the

instructor.

TABLE 2

Set circuit Total circuit Branch currents

voltage current (IT)

IB1 IB2 IB3

12 V I

136 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.52

TASK 3 : Verify the Kirchhoff’s Voltage Law with one voltage source

1 Measure and record in Table 3, values of resistors R , 4 Get the circuit connections and polarities marked,
4
R5 and R6 soldered on the lug board. checked by the instructor.
2 Make the circuit connections as shown in Fig 3. 5 Switch ON PSU and set output to 12V. Switch ON
SPST. Following the voltage polarities marked across
3 Mark the polarity of the voltage drops across resistors
the resistors, measure and record the voltage drop
R , R and R in the copy of Fig 3.
4 5 6 across resistors R , R & R in Table 3.
4 5 6
6 Switch OFF SPST and PSU.
7 Write Kirchhoff’s loop equations for the closed paths
a-c-d-b-a, a-e-f-b-a and c-e-f-d-a. Substitute the voltage
readings recorded in Table 3 in the equations for
verification.
8 Get your readings and equations checked by the
instructor.

TABLE 3

ed
Settle circuit Measured the value Voltage meaured across

bl I
voltage
pu M
ish
Re NI
be @
o ht
t t rig

_______
No py

TASK 4: Verify the Voltage Law with two voltage sources

Co

1 Modify the circuit connections made in Task 3, to 3 Set the output of PSU-1 to 12 volts and PSU-2 to 6
obtain a circuit as shown in Fig 4. volts.
4 Switch ON both SPSTs. Following the voltage polarities
Keep both the PSU’s and the two SPST’s in OFF
marked across the resistor, measure and record the
position while making circuit connections.
voltage drop across the resistors R , R & R in
4 5 6
Table 4.
2 Mark the polarity of the voltage drops across the
resistors R , R and R in the copy of Fig 4.
4 5 6 Note: While measuring voltage across resistor,
if the meter deflects below zero, recheck the
polarity marked at step 2 and repeat step 4.

5 Switch OFF the SPSTs and PSUs.

6 Write Kirchhoff’s voltage equations for the closed
paths a-c-d-b-a, a-e-f-b-a and c-e-f-d-c.
7 Get your readings and equations checked by the
instructor.

_______
Electronics & Hardware : Electronic Mechanic - Exercise 1.5.52 137
 TABLE 4

Set output of Set output of Voltage measured across

RPSU 1 RPSU 2
VR4 VR5 VR6

_______

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

138 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.52

Electronics & Hardware Exercise 1.5.53
Electronic Mechanic - Active and Passive components

Verify laws of series and parallel circuits with voltage source in different com-
binations
Objectives: At the end of this exercise you shall be able to
• verify laws of series circuits in different combinations
• verify laws of parallel circuits in different combinations.

Requirements
Tools/Instruments/Equipment Materials/components
• RPS (0-30 V) - 1 No • Resistors (0.5 watts) 1K,1.5K
• MC Voltmeter (0-10 V) - 2 Nos 6.8K - each 1 No
• MC Voltmeter (0 - 30 V) - 1 No • Connecting wires - as reqd
• MC Ammeter (0 -500 mA) - 1 No • Bread board - 1 No
• Digital multimeter - 2 No

PROCEDURE
TASK 1 : Verify laws of series circuits in different combinations.

ed
bl I
pu M
1 Arrange the apparatus as per the circuit diagram in

ish
Note: The value must be kept constant
bread board as shown in Fig 1.
throughout the test by connecting Voltmeter
Re NI
across the voltage supply in the circuit to ob-
serve the voltage.
be @

4 Determine the zero error and least count of the am-

meter and voltmeter and record them.
o ht

5 Switch ON the power supply.

t t rig

6 Set the voltage to 10V in RPS.

7 Record the reading of the Ammeter and Voltmeter
No py

in Table - I.
2 Connect the circuit with help of connecting wires.
Co

8 Repeat the steps 1 to 7 for different voltages (5V,15V).

3 Make the connections as per circuit diagram, all con-
nections must be neat and tight , take care to connect 9 Get the work checked by the Instructor.
the Ammeter and Voltmeter with their correct polarity
(+ve to +ve and -ve to -ve).

Table-1

1K 1.5K 6.8K 82Ω 100Ω 150Ω

V (volt) VT=

Ι (mA) IT=

139
TASK 2 : Verify laws of parallel circuits in different combinations

1 Arrange the apparatus as per the circuit diagram 4 Determine the zero error and least count of the
in Bread board as shown in Fig 2. Ammeter and Voltmeter and record them.
5 Get the work checked by the Instructor
6 Switch ON the power supply.
7 Set the voltage to 10V in RPS.
8 Record the readings of the ammeter and voltmeter
in Table-II.
9 Repeat the steps 1 to 7 for different voltages (5V,15V).

2 Connect the circuit with help of connecting wires.

3 Make the connections as per circuit diagram, all
connections must be neat and tight. Take care to
connect the Ammeter and Voltmeter with their correct
polarity (+Ve to +Ve and – Ve to –Ve).

Table-2

1K 1.5K 6.8K 82Ω 100Ω 150Ω

ed
VT=
Ι (mA)

bl I
pu M
ish
V (volt) IT=
Re NI
10 Get the work checked by the Instructor.
be @

_______
o ht
t t rig
No py
Co

140 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.53

Electronics & Hardware Exercise 1.5.54
Electronic Mechanic - Active and Passive components

Measure the resistance, voltage, current through series and parallel connected
network using Multimeter
Objectives: At the end of this exercise you shall be able to
• measure the resistance in series networks using Multimeter
• measure the resistance in parallel networks using Multimeter
• measure the voltage in series networks using Multimeter
• measure the voltage in parallel networks using Multimeter
• measuring the current in series networks using Multimeter
• measuring the current in parallel network using Multimeter.

Requirements
Tools/Instruments/Equipment Materials/components
• RPS (0-30 V) -1 No • Resistors (0.5 Watts) 10K - 3 Nos
• Digital multimeter - 2 Nos • Resistor (0.5 Watts) 4.7K - 1 No
• Resistor (0.5 Watts) 12K - 1 No
• Connecting wires - as reqd
• Bread board - 1 No

ed
bl I
pu M
ish
PROCEDURE
Re NI
TASK 1 : Measure the resistance in series networks using Multimeter
1 Plug the black probe into the COM port on your multi 3 Turn the multi meter knob to the Resistor/Continuity
be @

meter as shown in Fig 1. mode as shown in Fig 3.

o ht

Fig 1 Fig 3
t t rig
No py
Co

4 Turn on the multi meter.

2 Plug the red probe into the VΩmA port as shown in
Fig 2. 5 Select the required range of the resisting in multimeter.
6 The Fig 4A is the resistor are connected in series
Fig 2
networks.
7 Place the one 10K resistor in bread board as shown in
Fig 4B.

141
 Fig 4B 11 Connect the third 10 resistor in series of the second
10K resistor as shown in Fig 5C and read the value in
multi meter and note down the Table-I.
12 Use the different resistor connect in series, measure
the resistance and note down the value in Table-I.

Fig 5

Note: Don’t Switch ‘ON’ the RPS while

measuring the resistance.

8 Place the multi meter probes on both end the resistors.

9 Read the value of the resistor indicated in multimeter
as shown Fig 5A.
13 Get the work checked by the Instructor.
10 Connect the second 10K resistor in series of the first
10K resistor as shown in fig 5B and read the value in
multi meter and note down in the Table-I.

ed
Table I

bl I
S.No RI (Kilo ohms) R1+R2 (kilo ohms) R1+R2+R3 (kilo ohms)
pu M
ish
Re NI
be @
o ht

_______
t t rig

TASK 2 : Measure the resistance in Parallel networks using multi meter

1 Follow the steps 1 to steps 5 in Task 1. Note: Don’t Switch ‘ON’ the RPS while
No py

2 The Fig 1A is the resistors are connected in Parallel measuring the resistance.
Co

networks.
4 Place the multi meter probes on both end the resistors.
3 Place the one 10K resistor in bread board as shown
in Fig 1B. 5 Read the value of the resistor indicated in multimeter
as shown in Fig 2A.
A 6 Connect the second 10 K resistor in Parallel of the first
10K resistor as shown in Fig 2B and read the value in
multimeter and note down in the Table-II.
7 Connect the third 10 resistor in parallel of the second
10K resistor as shown in Fig 2C and read the value in
multi meter and note down in the Table-II.
Fig 2

Fig 1B

142 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.54

8 Use the different resistor, connect in series and
measure in the resistance and note down the value in
Table-1.
9 Get the work checked by the Instructor.
10 Use the formula of parallel circuits and calculate the
resistance value
1/RT = 1/R1 + 1/R2 + 1/R3 +....
Example : We have to calculate 2 resistances which are
connected in parallel and find out the total resistance for
values R1=6 ohms, R2=12 ohms.

Table II

ed
bl I
S.No 1/RT=1/R1 (Kilo ohms) 1/RT=1/R1+1/R2 1/RT=1/R1+1/R2+1/R3

pu M
ish
(kilo ohms) (kilo ohms)
Re NI
be @
o ht

_______

Task 3: Measure the voltage in series networks using multimeter

t t rig
No py

1 Arrange the apparatus as per the circuit diagram in Fig 2

bread board as shown in Fig 1.
Co

2 Give the connection as per the circuit diagram with

help of connecting wires.
3 Set the RPS voltage is 5V.
4 Note down the current rating shown in RPS. Fig 3

5 Get the work checked by the Instructor.

6 Plug the black probe into the COM port on your multi
meter as shown in Fig 2.
7 Plug the red probe into the VΩmA port as shown in
Fig 3.

Electronics & Hardware : Electronic Mechanic - Exercise 1.5.54 143

8 Turn the multi meter knob to the DCV or DC (V)voltage Fig 6
section as shown in Fig 4.

Note: Most multi meters power up in Auto range

mode. This automatically selects a measure-
ment range based on voltage present.

Fig 4

11 See the multi meter display and note the voltage

shown in multi meter and note down in the Table -III.
12 Repeat the step 10 for all other resistor and note down
the voltages in Table-III.
13 Get the work checked by the Instructor.
14 Set the different voltages and note down the reading
in Table-III.
Table III
9 Turn the knob to 20V as shown in Fig 5. RPS R1 R2 R3 Total(VT)
(volt) (V) (V) (V)
Fig 5

ed
bl I
pu M 10

ish
Re NI
15
be @

20
o ht

Total current = _____________________ (mA).

10 Place the multi meter probes in R1 resistor as shown
t t rig

in Fig 6.
_______
No py

TASK 4 : Measure the resistance in Parallel networks using multimeter

Co

1 Arrange the apparatus as per the circut diagram in

bread board as shown in Fig 1.

7 See the multimeter display and note the voltag.e

shown in multimeter and note down in the Table-IV
2 Give the connection as per the circuit diagram with 8 Repeat the step 7 for all other resistor and note down
help of connecting wires. the voltages in Table-IV.
3 Set the RPS voltage is 5V. 9 Get the work checked by the Instructor.
4 Get the work checked by the Instructor. 10 Set the different voltages and note down the reading
in Table-IV.
5 Follows the step 6 to step 9 in Task 3.
6 Place the multi meter probes in R1 resistor as shown
in Fig 2.

144 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.54

 Table IV
RPS R1 R2 R3
(volt) (V) (V) (V)

10

15

20

_______

TASK 5 : Measuring the current in series network using multimeter

1 Arrange the apparatus as per the circuit diagram in Fig 3

bread board as shown in Fig 1.

ed
bl I
pu M
ish
Re NI
2 Give the connection as per the circuit diagram with
be @

help of connecting wires.

3 Set the RPS voltage is 5V.
o ht

4 Get the work checked by the Instructor. Fig 4

t t rig

5 Plug the black probe into the COM port on your multi-
meter as shown in Fig 2.
No py

Fig 2
Co

Fig 5

6 Plug the red probe into the mA/A port as shown in

Fig 3.
7 Set the type of current AC or DC as shown in
Fig 4.
8 Turn the knob to 200mA.
9 Place the multi meter probes in R1 resistor as shownin
Fig 5.

Electronics & Hardware : Electronic Mechanic - Exercise 1.5.54 145

10 See the multimeter display and note the current Table-V
shown in multimeter and note down in the
Table-V. RPS R1 R2 R3
11 Repeat the step 10 for all other resistor and note down (volt) (mA) (mA) (mA)
the current in Table-V.
12 Get the work checked by the Instructor.
5
13 Set the different voltages and note down the reading
in Table-V.
10

15

20

_______
Task 6 : Measuring the current in parallel network using multimeter

1 Arrange the apparatus as per the circuit diagram in 7 See the multimeter display and note the current
Bread board as shown in Fig 1. shown in multimeter in the Table-VI.

ed
8 Repeat the steps 6 for all other resistors and note

bl I
down the voltages in Table-VI.

pu M
ish
9 Get the work checked by the Instructor.
Re NI
10 Set the different voltages and note down the reading
in Table-VI.
be @

Table-VI
o ht

2 Give the connection as per the circuit diagram with RPS R1 R2 R3

help of connecting wire. (volt) (mA) (mA) (mA)
t t rig

3 Set the RPS voltages is 5.

No py

4 Get the work checked by the Instructor.

5
5 Follows the step 5 to step 9 in Task 5.
Co

6 Place the multimeter probes in R1 resistor as shown 10

in Fig 2.

15

20

_______

146 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.54

Electronics & Hardware Exercise 1.5.55
Electronic Mechanic - Active and Passive components

Identify different Inductors and measure the values using LCR meter
Objectives : At the end of this exercise you shall be able to
• identify different types of Inductors by their appearance
• check the physical and electrical condition of inductors
• measure value of inductance using RLC bridge and Digital LCR meter.

Requirements

Tools/Equipments/Instruments Materials/Components
• Trainees kit - 1 Set • Assorted types and values of inductors - 6 Nos
• Inductance measurement • Hook up wires - as reqd
bridge of any type - 1 No./batch
• Digital LCR meter - 1 No./batch

PROCEDURE
1 Take any one inductor from the given assorted lot.

ed
Identify the type name, symbol and record it in If necessary solder hook up wires at the

bl I
terminals for ease of connecting the inductor
Table 1.
pu M
ish
across the test terminals. Use minimum lead
2 Check for any of the physical defect as listed below in length for connection as this length will add up
Re NI
the inductor. Record the observed defect(s) if any. value.
A Conductor broken in the winding.
be @

8 Balance the bridge as demonstrated by your instructor

B Coating on copper wire peeled off. and show it to your instructor before taking readings.
o ht

C Core cracked. 9 Record the measured value of the inductor in Table 1.

D Former broken. 10 Remove the inductor connected to the LCR bridge and
t t rig

3 Measure and record the resistance across the inductor connect it across the Digital LCR meter after setting
terminals. the Digital meter for inductance measurement. Record
No py

the inductance value shown by the digital meter.

If the resistance measured is very high or open
Co

the inductor is defective. Consult your instruc- Procedure for Instrument set up and
tor. measurement is not given due to various
varieties of Digital Meters used in different
4 Repeat steps 1 to 3 for atleast 5 to 10 more inductors. training institutes.
5 Get your work checked by your Instructor. 11 Compare the measured value of the inductor using
6 As demonstrated by your instructor, carry out necessary LCR bridge and digital LCR meter. Record the
settings on the given LCR bridge to measure Inductance difference in Table 1. Discuss reasons for difference
of an unknown inductor. Use internal 1KHz AC source in reading (if any) with your instructor.
of the bridge for inductance measurement. 12 Repeat the steps above and measure inductance of
atleast five different types of inductors and get your
Since training institutes have different types of
work checked by the instructor.
LCR bridges, and as each bridge has its own
specific type of controls/switches/jumpers,
procedure for setting up of bridge and
measurement are not given here.

7 Take any one of the inductor from the assorted lot.

Connect the inductor across the test terminals of the
bridge.

147
 Table - 1

Inductance value

Label Type/name Symbol Physical Resistance using using Difference

No of inductor defect (s) across coil LCR digital in reading
noticed terminals bridge meter between
bridge and
digital meter
(if any)

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

Air core inductor Iron core inductor

148 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.55

Iron powder inductor Laminated core inductor

Bobbin based inductor Toroidal inductor

ed
bl I
pu M
ish
Multi layer ceramic inductors Film inductor
Re NI
be @
o ht
t t rig
No py
Co

Variable inductor

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.5.55 149

Electronics & Hardware Exercise 1.5.56
Electronic Mechanic - Active and Passive components
Identify the different capacitors and measure capacitance of various capaci-
tors using LCR meters
Objectives : At the end of this exercise you shall be able to
• identify the different capacitors
• measure capacitance of various capacitors using LCR meters.

Requirements
Tools/Equipments/Instruments Materials/Components
• Trainees tool kit - 1 Set • Paper capacitors - as reqd
• Multimeter - 1 No • Electrolytic capacitors - as reqd
• Plastic film capacitors - as reqd
• Ceramic capacitors - as reqd
• Mica capacitors - as reqd

PROCEDURE
TASK 1 : Identify different capacitors by physical appearance and note down their specifications

ed
bl I
pu M
Assumption: A set of capacitors mentioned in

ish
this exercise are to be displayed on the work
Re NI
bench trainees are required to identify the
capacitors and write the specification in the
be @

table.
o ht

1 Identify different capacitors by physical appearance and note down their specifications.
t t rig

Sl. No Name of the capacitor Specifications Capacitance

No py

1 Paper capacitor
Co

2 Electrolytic capacitor

3 Plastic film capacitor

4 Ceramic capacitor

5 Mica capacitor

2 Get your work checked by the instructor.

150
 PAPER CAPACITORS ELECTROLYTIC CAPACITORS
ALUMINIUM TYPE
D
MF F
68 C 1μ C
0.0 0VD D
60 0V

10 μ F
47 μ F +
60
+

35V
2200 μ F + +
+
25V
METALLIZED TYPE +

100 μ F
2μ F
25V + +

6V

100V
87 DB +
(sealed in metal tube)
PAPER TUBULAR RANGE: 0.005 - 2 μ F
RANGE: 0.0001 - 2 μ F
+
1μ F +

DCWV: 200 - 600 VOLTS 6V +

DCWV: 100 - 1000 VOLTS UP TO 18 μ F AT 150 DCWV

100μ f 350 DCWV

MP

60μ f 350 DCWV

60μ f 350 DCWV
60μ f 350 DCWV
MP/05/1/400
1/400/40 DIN 41195

MP F
2 μ 0V
MP 08/8/630/2 60
8μ F+ -- 10%
630V
G8/630/40/ DIN 41197
TANTALUM TYPE
HPF 560-14/MPJ
25° / + 85°C 9.75 H
BATHTUB TYPE WET TYPE POLARISED
RANGE: 0.05 - 2 μ F 100 μ F
25V
DCWV: 600 VOLTS

+
+
+
+
3.3 μ F +
75V +

CERAMIC CAPACITORS
DRY TYPE POLARISED
DISC
+22
33 33 35V +15

ed
02 .0015 10% 10% 0.5MFD
X2 35V

bl I
2. 5V
2
μ
3

F
+
pu M +1

ish
35V
Re NI
TUBULAR PIN - UP
be @

PLASTIC FILM CAPACITORS

o ht
t t rig

022
63 TC/K
1
0.0 V =
400
No py

022
FEED - THROUGH FLAT 63
Co

27P

MICA CAPACITORS
STAND - OFF
10P STACKED MICA
RANGE: SPF - 10,000PF

SILVERED MICA
RANGE: 5PF - 0.01 μ F
DCWV: 500 volts
MONOLYTHIC CHIP BUNDELED TUBE

HEAVY - DUTY MICA

BUTTON 500 PF @ 12,500 volts
TO 0.1 F @ 500 volts

_______
Electronics & Hardware : Electronic Mechanic - Exercise 1.5.56 151
TASK 2 : Measure capacitance of various capacitors using LCR meter

1 Connect the LCR meter with the capacitor.

2 Measure the capacitance and record it in the Table.
3 Get your work checked by the Instructor.

Sl. No Name of the capacitor Values of the Reading of the

capacitor in found capacitor

1 Paper capacitor 20 KPF

2 Electrolytic capacitor 100 MFD/50V

3 Plastic film capacitor 0.1 MFD/

4 Ceramic capacitor 0.01 nED

5 Mica capacitor 10 KPF

ed
bl I
pu M
ish
Re NI
_______
be @
o ht
t t rig
No py
Co

152 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.56

Electronics & Hardware Exercise 1.5.57
Electronic Mechanic - Active and Passive components
Identify and test the Circuit breaker and other protective devices
Objectives : At the end of this exercise you shall be able to
• identify the terminals of MCB
• connect the terminals of MCB and test its functioning
• identify the terminals of ELCB
• connect the terminals of ELCB and test its functioning.

Requirements
Tools/Equipments/Instruments Materials
• Cutting plier 150mm - 1 No • 10W 1Ω wire wound variable
• Screw driver 150mm - 1 No resistor - 1 No
• 5KΩ 1W fixed resistor - 1 No
• Electrician knife 100mm - 1 No • Push button switch - 1 No
• Wire stripper 150mm - 1 No • Water Rheostat /Lampbank - 1 No
• MI Ammeter (0-10A) - 1 No
• MI Ammeter (0-100mA) - 1 No
Equipments/Machine

ed
bl I
• MCB 240 V/16 A, 2 pole - 1 No

pu M
ish
• MCB 440 V/32 A, 3 pole - 1 No
• ELCB 240 V/25 A, 2 pole
Re NI
with tripping current 30mA - 1 No
be @

PROCEDURE
o ht

TASK 1: Identify the terminals of MCB and test its functioning

t t rig

1 Collect MCB from instructor and read its specification 2 Wire up the circuit as shown in the circuit diagram as
given on it (Fig 1). shown (Fig 3).
No py

Fig 1
Co

153
3 Switch on the main supply 5 Press the test switch and vary the variable resistance
and note the current.
4 Close the switch S1 and operate the water rheostat or
lamp bank till the Ammeter. A reads about 5A current 6 Record the current at which the MCB trips off………

Keep variable resistance RS in full cut in

position.

_______

TASK 2 : Identify the terminals of ELCB and test its functioning

1 Collect the ELCB from your instructor and read its 2 Wire up the circuits as shown in the circuit diagram as
specification given on it (Fig 2) shown in diagram 3
3 Switch on the main supply keeping the MCB and
ELCB in ON position
4 Close switch S1 and operate the water rheostat lamp
bank till the ammeter. A reads about 5A current
5 Press the test switch and vary the variable resistance
and note the leakage current and record...
6 Record the leakage current or which the ELCB trips
off..................

ed
7 Test the ELCB for trip function by operating the test

bl I
pu M button. In the cast the ELCB must trip off when the

ish
button is pressed
Re NI
be @
o ht

_______
t t rig
No py
Co

154 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.57

Electronics & Hardware Exercise 1.5.58
Electronic Mechanic - Active and Passive components
Dismantle and identify the different parts of a Relay
Objectives : At the end of this exercise you shall be able to
• dismantle the given relay
• identify the parts of a relay given to you
• trace the circuit diagram of the relay and draw its wiring diagram
• assemble the relay and test for its operation.

Requirements
Tools/Equipments/Instruments Materials
• Trainees tool kit - 1 Set • PVC flexiable cable 14/0.2mm - 5 meter
• Multimeter - 1 No • PVC Insulated copper cable
4sq.mm - 5 meter
Equipments/Machine
• Electro mechanical relay - 1 No

PROCEDURE

ed
TASK 1 : Identify the parts of a electro mechanical relay and draw its wiring diagram

bl I
pu M
ish
1 Pick up an electro mechanical relay and record its 4 Record the specifications of the relay coil.
Re NI
lable number.
5 Identify the number of contacts.
2 Dismantle the relay.
6 Find the rated operating voltage of the relay.
be @

3 Identify the parts and record them in your notebook

7 Sketch the relay diagram in your note book.
(Fig 1).
o ht

8 Assemble the relay and test for its operation (Fig 2).
t t rig

Fig 2
No py
Co

_______

155
Electronics & Hardware Exercise 1.5.59
Electronic Mechanic - Active and Passive components
Connect a timer relay in a circuit and test for its working
Objectives : At the end of this exercise you shall be able to
• connect and test the timer relay using IC 555.

Requirements
Tools/Equipments/Instruments Materials
• Trainees tool kit - 1 Set • Bread board - 1 No
• Multi meter - 1 No • 555 Timer IC - 1 No
• Resistor 10K - 2 Nos
Equipments/Machine • Resistor 560Ω - 1 No
• RPS (0-30V) - 1 No • Variable resistor 100K - 1 No
• Capacitors 100nF, 0.01 nF - Each 1 No
• Diode 1N4004 - 2 Nos
• LED - 1 No
• Transistor BC548 - 1 No
• Toggle switch - 2 Nos
• 12V Relay - 1 No
• Resistor 1KΩ - 1 No

ed
bl I
PROCEDURE
pu M
ish
TASK 1 : Connect and test the timer relay using IC 555.
Re NI
1 Check the given Bread board. 7 Place the capacitor in their locations.
be @

2 Identify the IC and other components. 8 Insert the relay in place.

3 Insert the diode, care needs to be taken to ensure the 9 The switch a attached to either trigger on high and
o ht

correct polarity. +12V (or) trigger on low and 0V. Connect the switch
with wire to its Bread board.
t t rig

4 Insert the IC socket taking care to orientate the localing.

10 Adjust the legs of the IC 555 to match the socket width.
5 Observe the terminals transistor BC548.
No py

11 Insert the IC with the locating dot as shown in the

6 Care needs to ensure the LED is inscrted with the
diagram.
correct polarity.
Co

12 Connect a 12V power source.

_______
156
Electronics & Hardware Exercise 1.5.60
Electronic Mechanic - Active and Passive components

Connect a Contactor in a circuit and test for its working

Objectives : At the end of this exercise you shall be able to
• identify the parts of contactor
• connect the contactor in a circuit & test for its working.

Requirements
Tools/Instruments Materials
• Combination pliers 200mm - 1 No • PVC insulated cable, 2.5 sq.mm
• Screwdriver 150mm - 1 No 650 V grade - 10 m
• Connector screwdriver 100mm - 1 No • Magnetic contactor, 3-phase
• Electrician’s knife - 1 No 20 A, 230 V - 1 No
• Round nose pliers 150mm - 1 No • 'ON' and 'OFF' push button stations,
• Multimeter - 1 No having one (normally closed) and one
• Voltmeter 300 V, AC - 1 No (normally open) contacts in each set - 1 No
• Ammeter 500m A, AC - 1 No • Test lamp 40 W, 230 V - 2 Nos
• Electrical drilling machine 6mm - 1 No • Laminated boards of size 200mm.
(L) X 150mm. (B) X 3mm. (T) - 3 Nos
Equipment/Machines

ed
• Machine screws 2 BA 25mm long with
• Dimmerstat/auto-transformer/variac two washers and nuts - 10 Nos

bl I
230 V/(0-270V)
pu M - 1 No

ish
Re NI
PROCEDURE
be @

TASK 1 : Identify the parts of the contactor and their operation

o ht

1 Inspect visually the given contactor. Schematic diagram given in Table 1 is for a
2 Identify the mounting holes for fixing screws. particular contactor. The contactor given to
t t rig

you may have different identification marks. If

3 Dismantle the contactor carefully. so, strike off the given numbers and incorpo-
rate the new numbers/letters by the side of the
No py

4 Identify the parts like protective housing, contact sup-

ports, main and auxiliary contacts, no-volt coil, arma- given numbers or otherwise draw a new sche-
matic diagram as implied in working step 5 of
Co

ture, yoke, springs etc.

Task 1. Likewise change the identification
5 After a careful study, draw the schematic diagram for
given in the column ‘Conditions between ter-
the given contactor in Table 1 in the space available
minals as ’ in Table 1.
just below the sample schematic diagram.
6 Identify the incoming and outgoing terminals of the 12 To determine the minimum voltage required for the
power circuit. Note down the same in Table 1. operation of the no-volt coil, first position the contactor
on the laminated board and mark the fixing holes.
7 Assemble the contactor and check the operation of the
moving magnetic core and the moving contacts by 13 Drill holes in the marked places with the help of an
using hand pressure. electrical drilling machine.
8 Trace and check the terminal connections to the fixed 14 Fix the contactor on the laminated board with the help
contacts. of machine screws.
9 Check the continuity between incoming and outgoing 15 Fix the laminated board with the contactor in a vertical
terminals, when the contactor is open and when closed position on a wooden board of the working bench.
manually, and write in the Table 1.
16 Connect the no-volt coil circuit through an ammeter
10 Identify the no-volt coil and its connecting terminal. push-button, ON switch and a dimmerstat as shown in
Enter the details in Table 1. Fig 1.
11 Measure the resistance of a no-volt coil by the 17 Connect the two lamps L1 and L2 with the auxiliary
multimeter and write in Table 1. terminals 21,22,13 and 14 as shown in Fig 1.
18 Connect a voltmeter as shown in Fig 1.
157
 TABLE 1

Sl. Device Symbol Schematic Conditions Write whether

No. diagram between terminals open or close

1 Contactor Sample under open

(normal) condition
Identification 1 & 2.... _______
Incoming terminals 3 & 4....
__________
___________ 5 & 6.... _______
___________

Outgoing terminals
___________ 21 & 22 _______
___________ 13 & 14 _______
Under manually
closed condition
1 & 2.... _______

ed
3 & 4.... _______
5 & 6.... _______

bl I
pu M 21 & 22... _______

ish
13 & 14... _______
Re NI
2 No-volt coil a&b
Resistance
be @

value____ ohm
o ht

3 Terminals of Voltage
‘No’ volt coil rating
t t rig

__________ _______
__________ volt.
No py
Co

158 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.60

19 Keep the knob of the Auto-transformer (dimmerstat 23 If the magnetic contact does not hold, increase the
variac) in a low position such that the output is applied voltage in steps of 25V upto the rated voltage
approximately zero. of the No-volt coil and observe the operation by pushing
the ‘ON’ button in every step. Write your observation
20 Switch on the supply and slowly increase the voltage
in Table 2.
to 100V by turning the Auto-transformer knob.
Do not increase the voltage beyond 110% of the
Now the no-volt coil is connected across 100 V rating of the no-volt coil. Increase suitably the
AC though the operating voltage written on the applied voltage for a 415V no-volt coil.
No-volt coil is 230V or any other rating given in
your starter no-volt coil. 24 Write your conclusion.
If the contactor is not closed then the indication
a) The rating of the No-volt coil is ________ volts.
lamp L1 will be on and lamp L2 will be off.
b) The No-volt coil does not operate below ______
volt.
21 Push the ‘ON’ button. See whether the No-volt coil
c) The percentage of minimum voltage of operation
holds the movable contacts down.
with the rated voltage is _______.
If the magnetic coil holds (operates), this will d) What will happen if the No-volt coil is operated at a
be indicated by L1 off and L2 on. higher voltage rating?

22 Write your observation in Table 2.

TABLE 2

ed
Sl. Applied voltage Voltage Condition: Remarks:

bl I
No.
pu M
across the no- rating of Write about the Write about

ish
volt coil the no-volt holding of no- the observed
Re NI
coil volt mechanism noise etc.

1 100V
be @

2 125V
o ht

3 150V 230V
4 175V
t t rig

5 200V
No py

6 225V
7 250V
Co

Keep this voltage for a short duration only, if the coil is

rated for 230V.

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.5.60 159

Electronics & Hardware Exercise 1.5.61
Electronic Mechanic - Active and Passive components

Construct and test RC-time constant circuit

Objectives : At the end of this exercise you shall be able to
• identify the given components to the given circuit
• construct and test the RC- time constant
• record the output wave form and plot a graph.

Requirements
Tools/Instruments/Equipments Materials
• Trainees Kit - 1 No • Bread board - 1 No
• CRO Dual trace - 1 No • Resistor 300 Ω - 1 No
• Multimeter - 1 No • Capacitor 2 nf - 1 No
• Power Supply (0-60V) - 1 No

PROCEDURE
TASK 1 : construct and test RC-time constant circuit

ed
1 Check the resistor by using multimeter.

bl I
pu M
2 Check the capacitor by using multimeter.

ish
3 Assemble the components as per the circuit dia-
Re NI
gram.
4 Connect the power supply as per circuit diagram.
be @

5 Give the square wave input signal through CRO and

observe the output signal as a saw tooth wave.
o ht

6 Hence the given RC-time contant circuit is verified.

t t rig
No py
Co

7 Record the output waveform and plot a graph of

percentage of voltage (or) current VS time.

_______

160
Electronics & Hardware Exercise 1.5.62
Electronic Mechanic - Active and Passive components

Construct a RC differentiator circuit and convert triangular wave into square

wave
Objectives : At the end of this exercise you shall be able to
• identify the components to the given circuit
• test the RC differentiator circuit
• record the out put wave form and plot a graph.

Requirements
Tools/Instruments Materials
• Trainees kit - 1 No • Bread board - 1 No
• CRO dual trace - 1 No • Resistor 1.5 KΩ, 1/4W - 2 Nos
• Capacitor 10 nF - 2 Nos

PROCEDURE
TASK 1 : To test the RC differentiator circuit

ed
bl I
1 Check the given bread board.

pu M
ish
2 Check the components by using mutimeter.
Re NI
3 Place the components as per circuit diagram.
4 Connect the CRO in the circuit.
be @

5 Give the input signal as triangular wave and take the

output as square wave.
o ht

6 Record the output wave form and plot a graph of input

t t rig

voltage VS time.

Note : The we can see that the of the outout

No py

wave form depens on the ration of the pulse

width to the RC time constant. when RC is
Co

much larger (greater than 10 RC) than the pulse

width the output waveform resembles the
square wave of the input signal. When RC is
much smaller (less than 0.1 RC) than the pulse
width, the output waveform takes the fom of
very sharp and narrow spikes as shown above.
So by varying the time constant of the circuit
from 10 RC to 0.1 RC wecan produce a rangeof
different wave shapes.
Generally a smaller time constant.

_______

161
 ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

162 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.62

Electronics & Hardware Exercise 1.5.63
Electronic Mechanic - Active and Passive components

Construct and test Series and Parallel resonance circuit

Objectives : At the end of this exercise you shall be able to
• determine the resonance frequency of a given LC series circuit
• determine the circuit current at different frequencies
• plot a graph of frequency versus circuit current.
• determine the resonance frequency of a given LC parallel circuit.

Requirements
Materials/ Components Tools/ Equipment/ Instruments
• General purpose Lug board - 1 No • Trainees kit - 1 No
• Capacitor 0.1 μF - 1 No • CRO, 20 MHz - 1 No
• Inductor coil, around 40mH (Use • Function generator - 1 No
the solenoid coil made in unit 5) - 1 No
• Unknown value Inductor - 1 No
• LED with holder - 1 No
• Hook-up wires - as reqd

ed
bl I
PROCEDURE
pu M
ish
TASK 1 : Determine the resonance frequency of a given LC series circuit
Re NI
1 Measure and record the inductance of the coil.
LED may not be glow or may be very dim,
be @

2 Solder the components as shown Fig 1 to obtain a because the set frequency of 1 KHz may not be
simple series resonance circuit. Connect instruments the resonance frequency of the circuit.
o ht

as shown in Fig 1
5 Increase the frequency gradually and record the
t t rig

The LED inthe circuit is to get a visual indication resonance frequency for at which the circuit current
of the current through the circuit at different becomes maximum (LED glows brightly)
frequencies.
No py

This is the resonance frequency of the series

resonance circuit because at series resonance
Co

current I through th LC circuit will be maximum.

6 Compare and record the difference in the resonance

frequency calculated at step 3 and that measured in
step 5.
7 Vary the input frequency in steps of 500 HZ around the
resonance frequency and in each step record the
value of circuit current.
8 From the recorded readings of current in step 6, plot a
3 Knowing the values of L and C, calculate and record graph of frequency versus current and mark the
the resonance frequency of the series resonance resonance frequecy of the LC series circuit.
circuit. 9 Get the working of the circuit, recorded readings and
4 Set the output of the signal generator to 10Vrms and the graph checked by the instructor.
frequency to 1 KHz. Record the current, I through
the circuit.
_______

163
TASK 2 : Determine the resonance frequency of a given LC parallel circuit

1 Measure and record the inductance of the coil.

Ensure that the current through the circuit is
2 Solder the component as shown Fig 2 to obtain a around 10 to 12 mA and not more. If more
simple parallel resonance circuit. Connect components current is flowing, reduce the output level of
as shown in Fig 2. the signal generator. LED will glow at all
frequencies other than at the resonant
The LED inthe circuit is to get a visual indication frequency.
of the current through the circuit at different
frequencies. 5 Increase the frequency gradually and record the
resonance frequency f, at which the circuit current
becomes minimum (LED does not glows or glows very
dim).

This is the resonance frequency of the parallel

resonance circuit because at parallel resonance,
current I through the parallel LC circuit will be
minimum.

6 Compare and record the difference in the resonance

frequency calculated at step 3 and that measured in
step 5.
7 Vary the input frequency in steps of 500 Hz around the

ed
3 Knowing the values of L and C, calcualte and record resonance frequency and in each step record the

bl I
the resonance frequency of the parallel resonance value of circuit current.
pu M
ish
circuit.
8 From the recorded readings of current in step 6, plot a
Re NI
4 Set the output of the signal generator to 4Vrms and graph of frequency verses current and mark the
frequency to 1 KHZ. Record the current I through the resonance frequency of the LC parallel circuit.
circuit.
be @

9 Get the working of the circuit, recorded readings and

the graph checked by the instructor.
o ht

_______
t t rig
No py
Co

164 Electronics & Hardware : Electronic Mechanic - Exercise 1.5.63

Electronics & Hardware Exercise 1.6.64
Electronic Mechanic - Rectifiers

Identify different types of diode, diode modules and their specifications

Objectives : At the end of this exercise you shall be able to
• name of the given diode
• whether the given diode is Ge, Si etc
• the essential voltage, current ratings of the diode.

Requirements

Tools/ Equipment/ Instruments Materials/Components

• Semi conductor diode data book - 1 Copy • Different types of diodes - 20 Nos

PROCEDURE
5 As done in step 4, find and record the following
Assumption: A set of different types of diode
specifications of the picked diode from the data book
are to be displayed on the work bench. Trainees
are required to identify the diodes IF or If - Maximum average forward current
VF or Vf - Forward voltage drop at specified IF
1 Pick up any one of the given assorted diodes record

ed
the type, number printed on the diode in the Table 1 IS - Maximum forward surge current

bl I
pu M
ish
2 Refer diode data book and search for the type number IVT - Maximum reverse current at VR
of the picked diode
Re NI
Function normal use/application of the diode
3 In the row the identified diode type number in data
The coding used for function differs from data book to
book check for the column which indicates material or
be @

data book. Consult instructor in case of difficulty.

mat. Record the type of semiconductor used from the
following tips given below 6 Repeat steps 1 to 5 for atleast ten different types of
o ht

given diodes.
• If code or Si is printed it means the material used for
making the diode is silicon. 7 For the diodes and its identified specifications recorded
t t rig

in Table 1 refer diode data book or diode equivalents

• If code G or Ge-Germanium.
data book and identify one or two equivalent diode
No py

• If code se-selenium. types for each diode.

4 In the same row of the identified type number of the 8 Get your work checked by the instructor.
Co

diode, look for the column which indicated rated peak

reverse voltage abbreviated as VR or Vr or PIV. Find
and record the indicated value of rated peak reverse
voltage.

165
166
Table 1
Diode specifications and equivalents

Label Type number Material Rated Peak Maximum reverse Maximum average Forward voltage Maximum forward Symbol
No printed on Si/Ge/Se/ reverse current @ VR Ivr forward current drop @ IF VF surge current IS
diode Others voltage VR IF

Co
No py
t t rig
o ht
be @
Re NI
pu M
bl I
ish

Electronics & Hardware : Electronic Mechanic - Exercise 1.6.64

ed
Electronics & Hardware Exercise 1.6.65
Electronic Mechanic - Rectifiers

Test the given diode using Multimeter and determine forward to reverse
resistance ratio
Objectives : At the end of this exercise you shall be able to
• read the code printed on the diodes
• identify the type of package
• identify the diode terminals from the marking on them
• determine the forward to reverse resistance ratio of diodes
• identify good/bad diodes.
• identify the diode bridge module and terminals.

Requirements
Tools/Equipments/Instruments Materials
• Trainees kit - 1 No • Assorted types of diodes - 20 Nos
• Multimeter/Ohmmeter - 1 No • Diode Bridge - 5 Nos
• Red colour sleeve wire - 10 cms each
• Patch cords - as reqd

ed
bl I
PROCEDURE
pu M
ish
TASK 1 : Identify Diode package and terminals
Re NI
1 Pick any one diode from the given assorted lot. Record 3 For the chosen diode referring to Chart 1, identify and
the code number printed on the diode in Table 1. put a small red colour sleeve over the anode terminal
be @

of the diode.
2 For the chosen diode, identify and record the type of
package (such as glass/plastic/ceramic/metal etc.). 4 Repeat step 1 to 3 for atleast 5 diodes of different types
o ht

and get your work checked by the instructor.

t t rig

_______
No py

TASK 2 : Checking diodes using ohmmeter/multimeter

Co

1 Set the ohmmeter/multimeter to x100 ohms range.

Carryout resistance-zero-setting of meter.

Choose other ohms range if necessary.

2 Pickup one of the identified diodes in Task 1. Connect

the ohmmeter probes across the diode terminals as
shown in Fig 1a. Record the resistance reading shown
by the meter in Table 1.
3 Reverse the meter probes connected to the diode as
shown in Fig 1b and record the reading shown by the
meter in the Table 1.
4 From the readings noted in steps 2 and 3, calculate
and record the ratio between forward and reverse
resistance.
5 From the recorded information give your conclusion
about the condition of the diode. Use the tips given
below for making conclusion;

167
 - In good diodes, resistance will be less than 100 - Shorted diodes show zero or very low resistance
ohms in one direction and very high or almost in both directions.
infinity/open in the other direction. In the worst
- Open diodes shows infinity/open in both directions.
cases the ratio between low to high resistance
could be at least 1:1000. 6 Repeat step 2 to 4 for atleast ten more given diodes of
different types.

_______

TASK 3 : Packaging styles of different diodes

1 Pick a diode from the assorted diodes. 3 Repeat the same for different styles of diode packages
2 Identify its packaging style and record in Table 1.

Table - 1

Resistance value in Ratio between Condition

Code Number
Label Type of forward and reverse of diode
printed on one opposite
Number package resistance FIT/UNFIT
the DIODE direction direction

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

_______

TASK 4 : Identify the diode bridge module and terminals.

1 Pick a diode bridge. 3 Identify the input and output terminals by referring data
manual and record it on Table 2.
2 Record the code no in Table 2.

168 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.65

 Table -2

Label Number Code Number printed on the DIODE Bridge Type of package

4 Repeat the steps 1 to 3 for atleast 5 bridges.

ed
_______

bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.6.65 169

Electronics & Hardware Exercise 1.6.66
Electronic Mechanic - Rectifiers

Measure the voltage and current through a diode in a circuit and verify its
forward characteristics
Objectives : At the end of this exercise you shall be able to
• measure the voltage and current through a diode in a circuit
• verify the forward characteristics of a diode.

Requirements
Tools/Equipments/Instruments Materials
• Trainees kit - 1 No • Tag board - 1 No
• Regulated PSU, 0-30V, 1A - 1 No • Semiconductor diodes,
• DC milliammeter, 0-500 mA - 1 No 1N4007 or BY127 or equivalent - 1 No
• DC micro-ammeter, 0-10 μA - 1 No • Lamp, 6V, 300 mA - 1 No
• DC milli-voltmeter, 0-1000 mV - 1 No • Suitable type Lamp-holder - 1 No
• Multimeter - 1 No • Resistor, 470Ω, 1/2 W - 1 No
• Hook-up wires, Red, Black - 0.2m each
• Patch cords - as reqd

ed
bl I
PROCEDURE
pu M
ish
TASK 1 : Measure the voltage and current through a diode in a circuit.
Re NI
1 Check the physical and electrical condition of the
be @

given diode, resistor, lamp and lamp-holder.

2 Record the type number of the given diode in Table 1
o ht

3 Identify the anode and cathode terminals of the diode.

t t rig

Put a red wire sleeve to the anode terminal of the

diode.
No py

4 Measure and record the resistance of the lamp in your

note book.
Co

5 Solder the tested components on the tag board refer-

ring to-schematic and layout diagram given in Figs 1a
and 1b.
6 Get the wiring checked by your instructor.
7 Switch ON the PSU and set output to 6V. Check, if the
lamp glows. Record your observation in Table 2.
8 Measure and record the voltage across lamp VL,
forward voltage drop across diode Vd and current Id in
Table 2.
9 From the recorded readings and the observed lamp
status (GLOW/OFF), record your conclusion about
the behaviour of the diode as a switch (ON/OFF).
10 Switch OFF PSU. As shown in Fig 2, reverse the diode
connection. Replace the milliammeter by a (0-10)
micro-ammeter. Remove the (0-1000) mV meter con-
nected across the diode.
11 Repeat steps 7, 8 and 9.

170
 Measure Vd using multimeter in 10V range.
12 Switch OFF power to the circuit. Get your readings
checked by the Instructor.

TABLE 1
Diode Type number : __________
Forward resistance of diode : __________Ω
Reverse resistance of diode : __________Ω
Lamp resistance : __________Ω

Table 2

Type of diode Status of lamp Drop across Diode current Drop across Behaviour of diode (diode
biasing Glows/OFF diode V volts I mA lamp V volts as a switch (OFF/ON)
d d L

Forward

Reverse

ed
bl I
pu M
ish
_______
Re NI
TASK 2 : Verify the Forward bias characteristics of a diode
be @

1 Form the test circuit as shown in Fig 3. 2 Get the neatness of your wiring checked by the in-
structor.
o ht

3 Switch ON PSU and increase the output voltage of the

t t rig

PSU such that the diode drop Vf varies from 0 to 1V in

steps as given in Table 3. At each step record the
No py

values of If.
4 Switch OFF the PSU. For each set of recorded values
Co

of Vf and If, calculate and record the forward resist-

ance Rf of the diode.
5 From the recorded readings in Table 3, plot a graph of
Vf and If in graph sheet.
6 Get your work checked by the instructor.

Electronics & Hardware : Electronic Mechanic - Exercise 1.6.66 171

 Table - 2 Forward bias characteristics Complete the following sentences:
(From forward characteristics)
Forward drop Forward Forward diode 1 From the recorded readings in Table 3, the turn on
across diode current resistance voltage of the diode is _____________ volts.
V
V in mV I mA R = fΩ 2 From the turn on voltage level of the diode, the diode
f f f I
f
is made of _____________ semiconductor material.
100 mV
200 mV 3 Between V = 400 mV to V = 700 mV the change in
f f
current is _____________ ohms.
300 mV
400 mV 4 The forward resistance of a diode after V = 500 mV is
f
_____________ ohms.
500 mV
600 mV 5 The forward resistance of a diode after V = 700 mV is
f
_____________ ohms.
700 mV
800 mV
900 mV
1 Volt

ed
GRAPH : Forward characteristics

bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

_______

172 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.66

Electronics & Hardware Exercise 1.6.67
Electronic Mechanic - Rectifiers

Identify different types of Transformers and test

Objectives : At the end of this exercise you shall be able to
• identify different types of transformers
• read and interpret details of the name plate of different types of transformer
• test different types of transformers.

Requirements
Tools/Instruments • Berry type transformer - 1 No
• Step up transformer 115/230 V - 1 No
• MI Voltmeter (0-300) V - 2 Nos
• Step down transformer 230/115 V - 1 No
• MI Ammeter (0-10) A - 1 No
• Auto transformer IP 240 V
• MI Ammeter (0-100) mA - 1 No
OP (0-270) V, 5A - 1 No
• Ohmmeter (0-500) Ω - 1 No
Materials
Equipments / Machines
• Cotton Waste - as reqd
• Core type transformer - 1 No
• Shell type transformer - 1 No

ed
bl I
PROCEDURE
pu M
ish
TASK 1 : Identify different types of transformers
Re NI
1 Identify different types of transformers by physical
Assumption: A set of different types of trans-
be @

apperance and draw the diagram in table- 1

formers as given in this exercise are to be
displayed on the work bench. Trainees are
required to identify different types of trans-
o ht

formers and draw the sketch in the alloted

column.
t t rig
No py
Co

Table 1

Name of the Tansformer Diagram

1 Core type of transformer

2 Shell type transformer

3 Ring type Transformer

173
 Name of the Tansformer Diagram

4 Main frequency transformer

5 Audio frequency transformer

6 High frequency transformer

7 Poly phase transformer

ed
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ish
Re NI
8 Step up transformer
be @
o ht
t t rig

9 Step down transformer

No py
Co

10 Ideal transformer

11 Auto transformer

12 Berry type transformer

_______
174 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.67
TASK 2 : Identify different types of transformers
1 Find out the corresponding terminals of a step down 4 Check and set the auto transformer at zero volt output
transformer by using a ohmmeter. position.
2 Determine HT and LT windings by measuring resis- 5 Switch on ‘S2 and adjust the auto transformer to get the
tance with the ohm meter. output voltage V1 = 100 Volts and read V2 and record
the value in Table -2.
LT winding will have low resistance
The output voltage of the auto transformer
Record resistane of both pair should be adjusted to about 50% of the rating
1st Pair ohms. This is HT/LT winding of the HT side.
2nd Pair ohms. This is HT / LT winding 6 Set the V1 value for the values indicated in Table 2 and
3 Connect the auto transformer and voltmeters to the record the corresponding readings of V2 in Table 2
transformer as shown in Fig.1
Table 2
S No. V1 V2

1 100 V

2 125 V

ed
3 150 V

bl I
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ish
4 200 V
Re NI
5 230 V
be @
o ht
t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.6.67 175

 TYPES OF TRANSFORMERS

ed
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ish
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Co

176 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.67

 Autotransformer

ed
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pu M
Berry Type Transformer

ish
Re NI
be @
o ht
t t rig
No py

_______
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.6.67 177

Electronics & Hardware Exercise 1.6.68
Electronic Mechanic - Rectifiers

Identify the Primary and Secondary Transformer windings and test the polarity
Objectives : At the end of this exercise you shall be able to
• read and interpret the name plate details of single phase transformer
• find out the polarity of the transformer.

Requirements
Tools/Instruments
• MI Voltmeter (0-300) V - 2 Nos
• Ohmmeter (0-500) Ω - 1 No
• MI Ammeter (0-10) A - 1 No
• MI Ammeter (0-100) mA - 1 No
• Push botton switch - 1 No
• 12 V battery - 1 No

PROCEDURE
TASK 1 : Identify the primary and secondary winding of a transformer.

ed
bl I
1 Find out the corresponding terminals and two wind- 2 Determine HT & LT winding by measuring resistances
pu M
ish
ings (HT & LT) with ohm meter as shown in Fig 1 by with the ohmmeter.
checking the continuity
Re NI
LT windings will have low resistance;mark ac-
cordingly.
be @

3 Record resistance of both parts

o ht

1st pair -------- ohms. This is HT/LT winding

2nd pair-------ohms. This is HT /LT winding
t t rig
No py

_______
Co

TASK 2 : Test the polarity of a transformer

1 Connect DC supply to HT through push button switch 3 Mark HT terminals as A1 and A2

2 Connect voltmeter to LT as shown in Fig 2 4 Mark LT terminals as a1 and a2
5 Press the push botton switch.
6 Observe the deflection of the pointer of the voltmeter.
If the pointer deflects in the right direction,retain the
markings made on terminals.
7 Change the voltmeter connections made to LT termi-
nals and change the marking made on LT terminals if
the deflection is in the reverse direction.
8 Now press the push button switch once again and
observe that the voltmeter deflecting in right direction.

_______

178
Electronics & Hardware Exercise 1.6.69
Electronic Mechanic - Rectifiers

Construct and test a Half-wave, Full wave and Bridge rectifier circuit
Objectives: At the end of this exercise you shall be able to
• construct a and test half-wave rectifier
• determine the output DC voltage
• measure voltage levels
• measure waveform parameters using CRO
• construct and test a full wave rectifier
• construct and test a bridge rectifier.

Requirements
Tools and Instruments • Step-down transformer, (Center,tap)
240V 24V 500mA - 1 No
• Trainees kit - 1 No
• Multi strand wire, Red, Blue 23/0.2
• Oscilloscope, 20 MHz, dual trace - 1 No
of 250V grade - as reqd
• MC Voltmeter 30V - 1 No
• Bread board - 1 No
• Multimeter - 1 No
(Laminated board 30x15x3mm)
• Soldering iron 25W/240V - 1 No
• Mains cord 3 core cable
Materials/Components 23/0.2 of 250V grade - 1 No

ed
• Tug board General purpose 5 points - 1 No • Nuts, bolts and washers - as reqd

bl I
• 3 pin plug 5 A 250 V - 1 No
• Diode 1N4007
pu M - 4 Nos

ish
• Resistor 470W - 1 No • Resin core solder 60/40 - as reqd
Re NI
PROCEDURE
be @

TASK 1 : Construct and test a Half wave rectifier

o ht

1 Test the continuity of the primary and secondary 2 Referring to Fig 1 follow the order of steps given below;
windings of the given transformer. Exchange, if found
- Mount the tested transformer as shown in Fig 1 on
t t rig

defective. Record the specifications of the given

bread board using suitable size nuts, washers and
transformer in the Table 1.
bolts. Get it checked by the instructor.
No py

TABLE 1
- Mount the rectifier diode on tag board by soldering
I Transformer specifications
Co

- Solder the wire connection and the three core

1 Type of transformer power cord as shown in Fig 1.
2 Rated primary voltage 3 Connect AC mains to the board and switch ON mains.
3 Rated secondary voltage Measure and record the mains voltage and trans-
4 Type of core former secondary voltage VS(rms) (AC input to rectifier)
5 Rated secodary current in the Table 1.
II Experimental details 4 Calculate and record the expected DC voltage across
1 Main supply voltage Vrms load RL using the formula,
2 Secondary voltage V(rms) Vrms Vdc = 0.45 Vs(rms)
(input to the rectifier) where, VS(rms) is the AC input to the rectifier.
3 Expected DC output Vdc volts
5 Measure and record the rectified DC voltage Vdc across
4 Measured DC output Vdc volts load RL using multimeter.
5 Difference of (3) and (4) volts
6 Record the difference in the calculated and measured
6 Peak value of input Vs(peak) volts values. Get it checked by the instructor.
7 Frequency of input signal HZ
7 Connect the two channel input, probes of the CRO as
8 Peak volume of pulsating shown in Fig 2. Set the volt/div and time/div of CH-1
DC Output volts and CH-2 such that the two waveforms are seen
9 Frequency of pulsating clearly.
DC output HZ
179
 ed
bl I
pu M
ish
Re NI
8 From the displayed waveforms on the screen, meas-
be @

ure and record the following parameters;

- Peak value of VS
o ht

- Frequency of VS
t t rig

- Peak value of pulsating Vdc

- Frequency of pulsating Vdc
No py

- Wave forms of output and input voltages

Co

9 Show the wave-forms and the recorded readings to

the instructor before switching OFF the half wave
rectifier and CRO.

_______

TASK 2 : Construct and test a Full wave retificer

1 Check and confirm good condition of the given Table 2

components. Record specifications of the transformer
in Table 2. Transformer Specifications

2 Construct a full wave rectifier circuit as shown in the 1 Rated primary voltage --------
schematic and layout diagram at Fig 3.
2 Rated Secondary voltage
3 Switch ‘ON’ the circuit. Measure the AC input voltage between centre tap and one end --------
V s(rms) to the rectifier across the center - tap and anyone
3 Rated Secondary current or VA
end of the transformer and record it in Table 3.
rating transformer --------
4 Calcualte the expected DC voltage Vdc across load RL
using the fornula given below;

180 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.69

In Full wave rectifier, Vdc = 0.9Vs(RMS) where, Vs(rms) - Peak value of VS
is the voltage across the centre-tap and any one end
- Frequency of VS
terminal of secondary. Record the value in Table 3.
- Peak value of pulsating Vdc
5 Measure the rectified output Vdc across load RL and
record it in Table 3. - Frequency of pulsating Vdc
6 Calculate and record the difference in the calculated - Wave forms of Output and Input voltages
and measured Vdc values. Get it checked by your 8 Show the wave forms and recorded readings to your
instructor. instructor before switching OFF mains supply and
7 Using a CRO measure and record the following CRO.
parameters in Table 3.

ed
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ish
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Co

Table 3
Readings of two-diode Full wave rectifier

Vs(rms) Calculated Measured Difference of Peak value Frequency Peak value of Frequency
Vdc Volts Vdc Volts (2) & (3) of Vs of Vs pulsating Vdc pulsating Vdc

(1) (2) (3) (4) (5) (6) (7) (8)

Electronics & Hardware : Electronic Mechanic - Exercise 1.6.69 181

TASK 3 : Construct and test a Bridge rectifier

1 Modify the two diode full wave rectifier wired in Task 1 5 Record the difference in the calculated and measure
to construct a bridge rectifier, referring to the schematic values in Table 4. Get it checked by your instructor.
and layout diagrams shown in Fig 4.
6 Using a CRO measure and record the following
2 Switch ON the circuit. Measure and record the AC parameters in Table 4.
inputV s(rms) to the rectifier in Table 4.
- Peak value of Vs.
3 Calculate the expected output DC voltage V dc across - Frequency of Vs.
load RL using the formula, in a bridge rectifier. - Peak value of the pulsating Vdc.
- Frequency of pulsating Vdc.
Vdc = 0.9Vs(rms) where, Vs(rms) is the AC input to the
- Waveforms of output and input voltages.
rectifier (refer Fig 4). Record the value in Table 4.
7 Show the waveforms and recorded readings to your
4 Measure the DC output V dc across the load RL and
instructor before switching OFF mains supply and
record it in Table 4.
CRO.

ed
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ish
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No py
Co

Table 4
Readings of Bridge Rectifier

Vs(rms) Calculated Measured Difference of Peak value Frequency Peak value of Frequency
Vdc Volts Vdc Volts (2) & (3) of Vs of Vs pulsating Vdc pulsating Vdc

(1) (2) (3) (4) (5) (6) (7) (8)

182 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.69

Electronics & Hardware Exercise 1.6.70
Electronic Mechanic - Rectifiers

Measure ripple voltage, ripple frequency and ripple factor of rectifiers for
different load and filter capacitors
Objectives : At the end of this exercise you shall be able to
• determine value of C for a given load current
• wire and test a full wave bridge rectifier with capacitor- input filter
• measure the ripple factor at different loads.
• measue the ripple voltage at different loads
• measure the ripple frequency at different loads.

Requirements
Tools/Equipments/Instruments Materials
• Trainees kit - 1 No • Bread board wired full wave bridge
• CRO, dual trace, 20 MHz - 1 No rectifier - 1 No
• DC Ammeter (0-500 mA) - 1 No • Hook-up wires (red and black) - as reqd
• Digital Multimeter - 1 No • Resistors, 470Ω, 5Ω and
220Ω, 5W - 1 each
• Electrolytic capacitor - as reqd

ed
bl I
pu M
ish
PROCEDURE
Re NI
1 To construct bridge rectifier assuming a load current, where, f is the supply frequency in Hz, 50Hz
IL of 80mA, calculate and record the value of filter
C is capacitance in μFarads
be @

capacitor to be connected. Assume 10% rule for

ripple. RLis resistance in ohms
o ht

2 Choose a standard value capacitor close to the calcu- To find % ripple factor (% r), multiply calculated r by 100.
lated value of C in step 1. Get it checked and approved 5 Switch ON the circuit. Measure and record values of
t t rig

by the instructor. Record the chosen standard value Vdc and IL in Table 1. From the measured value of IL,
capacitor. recalculate and record the peak-to-peak ripple Vr(p-p)
No py

3 Collect the capacitor and insert it on the bread board using the formula,
as shown in Fig 1. Connect (0-500) mA ammeter as IL
Co

shown in Fig 1. Vr(p – p)

≤
fC
r
6 Using CRO, referring Fig 2, measure and record the
following parameters in Table 1;
– Peak value of pulsating DC, Vout(peak)
– Peak-to-peak value of ripple Vr(peak-peak)

4 From the values of RLand C used, calculate and record

the theoretical value of ripple factor r, using the for-
mula,

1 2887
r= (For full-wave rectifier) or r =
4 3 fR C RC
L L

183
7 From the measured values using CRO, calculate and record 9 Get your readings checked by the instructor.
the values of Vdc and % ripple factor r using the formula;
10 Change the value of load resistor RLfrom 470Ω to
V 220Ω, 5W and repeat steps 1 to 9.
r(p – p)
Vdc = Vout(peak) –
2 When 220Ω is connected as load, the load current will be
Vr(rms) V approximately, 34V/220W= 154mA. Hence, at step 1,
r(p – p)
%r = x100 where, Vr(rms) = take 160mA as load current to calculate the value of C.
V dc 2 3
8 Compare and record the difference in Vdcmeasured
using meter (at step-5) with the calculated value of Vdc
using Vout(peak) and Vr(p-p) (at step 7).

1) Type of rectifier : ______________________

2) Calculated value of C, for a load of 80mA : ______________________

a) Nearest standard value of C chosen : ______________________

b) Recalculated value of ripple voltage Vr(p-p) : ______________________

for the chosen standard value of C
c) Calculated value of % ripple factor, r : ______________________

ed
bl I
pu M Table 1

ish
Using meter Using CRO From CRO readings Difference Difference
Re NI
Difference
Load inV using in calculated in calculated
I V V V V V V dc
L dc out(peak) r(p-p) r(p-p) r(rms) dc and mea- and found
RL Ω
be @

meter and sured value value of

mA volts CRO of V %r
r(p-p)
o ht

470 Ω
t t rig
No py

220 Ω
Co

3 Calculated value of C, for a load of 160mA : _____________________________

a) Nearest standard value of C chosen : _____________________________

b) Recalculated value of ripple voltage V

r(p-p)
for chosen standard value f C : _____________________________

c) Calculated value of % ripple factor r : _____________________________

_______

184 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.70

Electronics & Hardware Exercise 1.6.71
Electronic Mechanic - Rectifiers

Identify and test Zener diode

Objectives : At the end of this exercise you shall be able to
• identify and read specifications of a zener using the data book
• check the condition of the zener using an ohmmeter
• identify the terminals of zener diodes
• check zener action varying the input voltage.

Requirements

Tools/Equipments/Instruments Materials
• Trainees kit - 1 No • Assorted types of zener diodes - 20 Nos
• Power supply, (0-30V) ,1A - 1 No • 12V, 400mW, Zener diode, 1Z12
• DC milliammeter, (0-50 mA) - 1 No or equivalent - 1 No
• Digital Multimeter - 1 No • Resistor 47Ω, 1/2W - 1 No
• Resistors, 2.2K, 1K, 820Ω - 1 each
• Zener diode data book - 1 No

ed
bl I
PROCEDURE
pu M
ish
Re NI
1 Take one of the given zener diodes. Record its label
number and the component code number in Table 1.
be @

2 Check and record the working condition of the zener in

a similar way as you test a rectifier diode.
o ht

If you don’t know which terminal (+ve or -ve) of

multimeter is connected to the +ve of the internal
t t rig

battery, Check using another voltmeter and

make a mark on your meter.
No py

3 From the polarity marking on the body of the zener and

Co

from the test carried out at step 2, identify and put a

yellow sleeve to the cathode terminal of the zener.
4 Record the following specifications of the zener diode
under test;
9 Vary the input to zener VIN in steps as given in Table 3
– Nominal zener voltage, VZ and at each step record the values of VR, VZ and IZ in
– % tolerance Table 3. After taking readings, switch OFF PSU.

– Maximum power dissipation, PZ(max) 10 From the recorded readings in Table 3, calculate and
record the resistance RZ of the zener, and power
– Zener current, IZ dissipated PZ for each set of reading taken.
– Resistance of zener in zener mode, RZ 11 Get your recorded readings checked by the in-
– Type of package structor.

5 Get your work checked by the instructor. 12 Switch ON PSU. Set VIN to 25 volts. Measure and
record the no-load VOUT in Table 4.
6 Repeat steps 1 to 5 for atleast five different types of
zener diodes in the given lot. 13 Connect load resistors of values given in Table 4
across the output terminals and in ease case measure
7 Collect a 12 volt, 400mW (min) zener. Quick check its and record IL and output voltage VOUT.
condition, identify and put a yellow sleeve to its cathode.
Switch DC power supply OFF while changing the
8 Wire a test circuit as shown in Fig 1 on a general load resistors.
purpose lug board (Code:103-06-LB).

185
14 Calculate and record the output % load regulation at 15 Get your work checked by the instructor.
different loads using the formula,
16 Disconnect the circuit and return the components.
V –V
NL L
% Load regulation = x100
V
L

where, VLis the output voltage on load.

Table - 1

Specifications

Label Zener Condition Nominal % tolerance Max.power Zener Zener Type

No. code- from zener Pz current resistance of
number quick test voltage Vz Iz Rz package

Table - 2

ed
bl I
pu M Specifications

ish
Re NI
Code Condition Zener Condition Nominal % tolerance Max. Zener Zener Type
No. Code- from zener power current resistance of
number quick test voltage Pz Iz Rz package
be @
o ht
t t rig
No py

Table - 3
Co

Calculated value of Table - 4

Vin VR Iz Vz Rz Pz Vin at 25 volts constant
DC volts volts mA volts
RL Vz % load
15 volts regulator
open
16
2.2 K Ω
17
1KΩ

18 820 Ω

19 560 Ω

20

25
_______
186 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.71
Electronics & Hardware Exercise 1.6.72
Electronic Mechanic - Rectifiers

Construct and test Zener based voltage regulator circuit

Objectives : At the end of this exercise you shall be able to
• identify the polarity of a Zener diode by visual inspection.
• construct the Zener diode as per circuit diagram and test its condition.
• use Zener diode as a voltage regulator.

Requirements

Tools/Instruments Materials
• MC Voltmeter (0-25V) - 2 Nos • Zener diode 10V/ 1W - 1 No
• MC Ammeter (0-100mA) - 2 Nos • Zener diode (Assorted) - 5 Nos
• Digital Multimeter - 1 No • Resistors, 3K / 1W - 1 No
• Resin Core solder - as reqd
Equipments / Machine
• Hook up wire single stand - as reqd
• Regulated Power supply input • Resistors, 3Ω / 5W - 1 No
240V AC, output (0-30V) DC,1A - 1 No • PC Board, General Pattern - 1 No
• Diode data manual - 1 No

ed
bl I
PROCEDURE
pu M
ish
Re NI
TASK 1 : Identify the polarity of Zener diode and check its condition

1 Take one of the given zener diode. 4 Refer diode data manual and record the specifications
be @

of the zener diode under test in Table 1.

2 Check and record the working condition of the zener
diode. 5 Repeat steps 1 to 4 for atleast 5 different types of zener
o ht

diodes in the given lot.

3 From the polarity marking on the body of the zener
t t rig

identify and mark the cathode terminal of the Zener. 6 Get your work checked by the instructor.
No py

Table - 1
Co

Specifications

Sl Zener Condition Nominal % tolerance Max.power Zener Zener Type

No. code- from of zener Pmax current resistance of
number the zener voltage Vz Iz Rz package

_______

187
TASK 2 : Use a Zener diode as a voltage regulator

1 Construct the zener regulator circuit as shown in Fig 1 3 Switch ‘ON’ the power supply to the circuit and increae
the current by adjusting the potential divider R until the
2 Set the power supply to 15 volts.
ammeter (A2) reaches 20 milli-amperes.
4 Measure the supply voltage V1 and voltage across the
load V2. Measure the total current A1, and record in
Table 2.
5 Determine and record the range or variation of V2.
(Input voltage) over while V2. (Output voltage) remains
constant with in ± 0.1V of its value measure the
variation of A2 and A1 within this range and record in the
Table 2.

Table 2
Voltage Regulator

Measurement V2 volt A2 in mA A1 in mA V1 volts

V2 20

ed
V2 = + 0.1V

bl I
pu M
ish
V2 = - 0.1V
Re NI
be @

_______
o ht
t t rig
No py
Co

188 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.72

Electronics & Hardware Exercise 1.6.73
Electronic Mechanic - Rectifiers

Calculate the percentage regulation of Regulated power supply

Objectives : At the end of this exercise you shall be able to
• calculate the value of percentage regulation of regulated power supply
• wire and test the regulator power supply.

Requirements
Tools/Equipments/Instruments Materials

• Trainees kit - 1 No • Zener diode, (See note) - 1 No

• Multimeter - 1 No • Resistor (See note) - 1 No
• Bread board with wired bridge - 1 No
rectifier, and filter
• Wires sleeve, Red and black - 5 Cms

PROCEDURE

The values of zener diode and the resistor will

ed
have to be calculated by the trainee in this

bl I
pu M
exercise before collecting them.

ish
Re NI
1 To design a simple zener regulator to be connected at
the output of the bridge rectifier with the filter wired on
the breadboard. The required output specifications of
be @

the zener regulator are given below.

- Regulated output voltage : 12V DC ±0.5V
o ht

- Load current :
t t rig

Varying from No-load(0 mA) to 100 mA on full-

load.
No py

2 From the design calculations and referring to the diode 7 Test and record the regulated output voltage VOUT at
data book, identify at least two types of zeners match- No-load, 50% of rated full load and at 100% rated full
Co

ing the design requirement. Enter the zener type-code load.

in the O&T sheet.
Use the suitable value and wattage rheostat to
3 Get your calculations checked by the instructor. load the Output of power supply to 100mA.
4 Collect the zener and calculated value series limiting
resistor RSZ. Check the condition of the components. 8 Calculate and record % regulation at 50% and 100%
of rated maximum load current.
5 Connect the series resistor, RSZ and zener diode to
the power supply wired on the tag board as shown in 9 Get your work checked by the instructor.
Fig 1.
While doing the zener regulator design
6 Recalculate and replace the value of the current calculations, the additional current through
limiting series resistor RSL, used along with the output LED was not considered. This will not adversely
indicator LED. affect the design if the chosen zener and
services resistor wattage rating are slightly
over rated.

189
 Observation & Tabulation Sheet

1 a) Space for design calculations of simple zener regulator

Get it information and checked with your instructor

b) Specifications of zener diode chosen :

c) Specification of series resistor chosen :

2 Space for recalculation of the current limiting resistor RS for the LED.
Get it information and checked with your Instrutor.
3

Load Regulated O/P % load

Vout volts regulation

50%

100%

ed
_______

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ish
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be @
o ht
t t rig
No py
Co

190 Electronics & Hardware : Electronic Mechanic - Exercise 1.6.73

Electronics & Hardware Exercise 1.7.74
Electronic Mechanic - Basic Computer

Identify various indicators, cables, connectors and ports on the computer

cabinet
Objectives : At the end of this exercise you shall be able to
• identify various input/output devices connected to the computer
• identify different controls and ports on the system unit cabinet
• identify the internal parts of a system unit
• connect devices to related ports on the system unit.

Requirements
Hardware and software
• Computer - 1 No

TASK 1 : Identify different controls, ports and connectors on the system unit cabinet

The instructor will demonstrate the uses of the Table 1

following indicators ,switches controls (Fig 1)
SI. No Name the parts on the CPU Front Panel
and ports external to the processor found on

ed
the system unit shown in (Fig 2)and the train-
bl I
ees will make a record of it in Table 1 and 1
pu M
Table 2.
ish 2
Re NI

Fig
Fig12 3
be @

4
o ht

5
t t rig

6
No py

7
Co

10

Fig 2
Fig 3 11

12

13

14

15

16

17

191
 Table 2

SI. No Name the parts on the CPU Rear Panel

1
2
3
4
5
6
7
8
9
10
11

Chart 1

Description Application Cable/connector

ed
40 pin FRC male connector To connect MB with HDD
located on M/B
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py

34 pin FRC male connector To connect MB with FDD

Co

located on M/B

25 pin FRC male connector To connect MB with Parallel port

located on M/B provided on the rear side of the
PC

192 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.74

Description Application Cable/connector

10 pin FRC male connector To connect MB with serial port

located on M/B “D” connector provided on the
rear side of the PC

FDD cable (data) To connect MB with FDD

located inside the PC

ed
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pu M
ish
Re NI

HDD cable (data) To connect MB with HDD

located inside the PC
be @
o ht
t t rig
No py
Co

4 pin Molex connector SMPS to HDD, FDD, CDD

from SMPS unit

4 pin Berg connector SMPS to FDD (3 1/2”)

from SMPS unit

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.74 193

 Description Application Cable/connector

20 pin Berg connector SMPS (ATX) to MB

from SMPS unit

12 pin Berg connector SMPS (AT) to MB

5 pin DIN plug on key Key board to MB

board cable

ed
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ish
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5 pin DIN socket MB to key board

provided on the rear side
of the PC
be @
o ht
t t rig
No py

5 pin Miniature DIN plug Key board to MB

on keyboard cable
Co

5 pin Miniature DIN socket MB to key board

provided on the rear side
of the PC

PS/2 Key board connectors MB to Mouse, Mouse to MB

194 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.74

Description Application Cable/connector

15 pin High density VGA MB to Monitor

connector on the rear side
of PC

15 pin D type connector To connect Joy stick

ed
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D-25 pin male connector
ish
Serial port (Comport)
Re NI

on the rear side of the PC

be @
o ht
t t rig

D-9 pin male connector Serial port (Comport)

on the rear side of the PC
No py
Co

D-25 pin female connector Parallel port (Printer port)

on the rear side of the PC

Mini Jack socket Audio IN / MIC

on the rear side of the PC

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.74 195

 Description Application Cable/connector

Mini Jack from external External Audio Devices to

audio device Sound card

USB female connector MB to USB peripherals

provided on the rear side
of the PC

USB male connector from USB peripherals to MB

ed
the USB device

bl I
pu M
ish
Re NI
be @

Table 3
o ht

SI. No Name of the Connector/Cable 12

t t rig

1 13
No py

2 14
Co

3 15

4 16

5 17

6 18

7 19

8 20

9 21

10 22

11 23

24

196 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.74

Electronics & Hardware Exercise 1.7.75
Electronic Mechanic - Basic Computer

Demonstrate various parts of the system unit and motherboard components

Objectives : At the end of this exercise you shall be able to
• identify drives HDD, CD ROM drive, DVD-drive, USB pen drive and various secondary storage devices and
their usual maximum capacity for storage of information.

Requirements
Tools/Instruments Materials
• Screw driver set - as reqd • Sticking labels for marking
• Digital Multi-meter - as reqd cables & connectors - as reqd
Equipments
• Desktop PC with mouse & keyboard - as reqd
• Extra SATA and PATA Hard-Disk
Drive compatible cables - as reqd

ed
• In PC along with one PC along with one set of • All the cables internal to system unit (processing
bl I
I/O devices will be used for demonstration by unit) should be labelled along with (From - TO)
pu M
instructor
ish and male - female connectors are also to be la-
belled by same code with suffix "F"&"T"
Re NI

• Two PCs each with one set of I/O devices and

extra SATA HDD with cable, extra PATA DD with • All major components inside the processing unit
cable and one extra CD ROM drive / DVD ROM like - HDD, CD R/W drive, DVD R/W drive, CPU
be @

drive with cable, will be used by two groups of processor, ROM BIOS etc to be labelled.
trainees (each group of maximum 20 trainees
o ht

• Before opening the system unit processing unit,

one group for identification and other for cable
static charge of our body should discharge
connection)
t t rig

through earthing cable connected to body of dem-

• In the PCs used by trainees ensure that all the onstrator / user.
major components inside system unit are
No py

cabled such that trainees can idenfify referring

wall chart diagram
Co

PROCEDURE
TASK 1 : Identification of various drives and secondary storage devices in a PC

1 Remove cover of the system unit 4 Identify connection point at mother board for SATA
HDD, PATA HDD, CD R/W drive, and DVD R/W used
2 Observe hard disk drive type either SATA or PATA and
in desktop PC
its capacity, power connection cable, its voltage col-
umn colour code at cable with voltage supply used. 5 Identify different type cable connections used for dif-
ferent drive.
3 Identify desktop PC HDD, CD-R/W drive & DVD -
ROM drive, its connections for both type SATA and 6 Identify polarity of connector to avoid wrong connec-
PATA hard disk drive and its connection using straight tion.
cables, cross cable for making it primary master ei-
7 Fix the cabinet, switch on supply and check the sta-
ther, primary slave or secondary master / slave using
tus of computer.
suitable data cable.

197
 Fig 1 Fig 2

Floppy Drive DVD Drive

Fig 3 Fig 4

ed
bl I
pu M
ish
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be @
o ht

CD Drive Hard Disk Drive

t t rig

Fig 5 Fig 6
No py
Co

198 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.75

Electronics & Hardware Exercise 1.7.76
Electronic Mechanic - Basic Computer

Identify various computer peripherals and connect it to the system

Objectives : At the end of this exercise you shall be able to
• identify different controls on the processing unit cabinet
• identify various input/output devices connected to PC
• identify various ports available on PC for various devices.

Requirements

Hardware and software • Screw driver set and Allen key

(depending upon the type of
• Identical PCs with labeled ports,
connection cables fixing used with connectors) - as reqd
(could even be dummy) - as reqd • Sticking labels - as reqd
• I/O devices such as Keyboard, Mouse
Monitor, Printer, Multimedia, Speaker,
CD Drive, DVD Drive and Microphone - as reqd

One PC along with one set of I/O devices will

ed
•
be used for demonstrating by the instructor.
bl I
pu M
•
ish
Two PC’s each with one set of I/O devices
will be used by two groups of trainees(each
Re NI

group not exceeding a maximum of ten

trainees)
be @

PROCEDURE
o ht

Demonstration cum Practice

t t rig

Alphabetized steps are for the instructors, Numerical

No py

steps are for the trainees. For this exercise the computer
setup used by the trainees should not be ON unless other
Co

wise instructed in the steps.

TASK 1 : Identify the major components, Controls and Ports seen on the processing unit cabinet

A. Instructor will demonstrate the uses of the indicators, • Printer port, keyboard connector, monitor connector
switches, controls and Ports external to the processor
• Speaker socket
unit found on the cabinet of the processor unit as per
the list given below. • Universal serial bus port (USB)
• Mains power-on switch While demonstrating, the following points should be
Highlighted and stressed.
• Power on LED
• Function of each switch
• Reset button
• Function of each LED indicator
• HDD busy LED
• Function of each visible device
• Floppy Disk Drive, Disk eject button, Disk busy
LED • Function of each port
• CD Drive, CD busy/reading LED, controls and • Basic specification of DVD and CD drive
sockets found on the disk drive • Basic symptoms of healthy processor (fan sound,
• Ports for connecting the Mouse and other devices power light, any unusual noise/smell etc)
• Precaution to be taken while using the computer

199
 • Precaution to be taken while operating DVD and
CD drives
• Precaution to be taken while handling DVD and CD
• Precaution to be taken while handling and storing
the processor unit
_______

TASK 2 : Identify the I/O devices connected to PC

A. Instructor will demonstrate the controls of different I/O While carrying out the demonstration, the instructor should
devices connected to PC as per the list ensure the following points are highlighted,
• The Monitor Precautions to be taken for handling the danger
• The Printer 1 Record the I/O devices connected to the computer
setup given to you
• The Mouse
2 Record the manufacturer, type name and model name/
• The Keyboard
number of the I/O devices connected
• Multimedia speakers
3 Record against each device whether it is an input
• The microphone device or an output device
• The scanner 4 Get the recorded details of the devices checked by the
• The Modem instructor.

ed
•
bl I
Any other I/O devices available at the time of
pu M
ish
conducting this demonstration.
Re NI

_______
be @
o ht
t t rig
No py
Co

200 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.76

Electronics & Hardware Exercise 1.7.77
Electronic Mechanic - Basic Computer

Disable certain functionality by disconnecting the concerned cables SATA /

PATA
Objectives : At the end of this exercise you shall be able to
• disable the functionality from device manager
• disconnecting the devices from the mother board.

Requirements
Tools/Instruments Materials
• Screw driver set - as reqd • Sticking labels for marking
• Digital Multi-meter - as reqd cables & connectors - as reqd
• Static charge earthing cable
system - as reqd
Equipments
• Desktop PC with mouse & keyboard - as reqd
• Extra SATA and PATA Hard-Disk

ed
Drive compatible cables - as reqd

bl I
pu M
PROCEDURE
ish
TASK 1: Disabling device or USB device manager
Re NI

Fig 1
be @
o ht
t t rig
No py
Co

201
1 Click start menu of windows desktop screen 7 In properties window, select the drivers tab
2 Open control panel in start menu 8 Now click the button of disable for disabling the de-
vice.
3 Select and open device manager
9 Click the OK button on window
4 Now, locate device or port or USB or connector to
enable or disable. 10 Now you can disconnect concerned device connected
to connector
5 After finding the device or port or USB or connector,
select it and make mouse right click on device icon. 11 Check the worksheet by your instructor
6 Select and open the properties of device in right click
menu.

_______

TASK 2 : Disconnecting the devices from the motherboard

1 Open the cabinet of the desktop PC 4 Remove the cable connectors and check the status
on desktop.
2 Identify the port or USB cable connections on
motherboard by using motherboard diagram. 5 Check the work done by the instructor
3 Unlock if any protection screws are present on cable
connectors

ed
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pu M
_______

ish
Re NI
be @
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No py
Co

202 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.77

Electronics & Hardware Exercise 1.7.78
Electronic Mechanic - Basic Computer

Replace the CMOS battery and extend a memory module

Objectives : At the end of this exercise you shall be able to
• identify the battery information and type of battery
• remove the battery
• replace the battery
• identify the location of RAM (S1mm/D1mm)
• replace and extend the RAM.

Requirements
Tools/Instruments Materials
• Watch-maker screw driver set - 1 No • Quick guide or manual for motherboard
• Screw driver set - 1 No of P.C. showing diagram & its
components - 1 No
Equipments
• CMOS battery - 1 No
• Desktop P.C. with mouse and • Different types of RAM suitable
keyboard - 1 No to the motherboard - as reqd
• Extra mother board of computer - 1 No • Quick installation guide - 1 No

ed
bl I
pu M
PROCEDURE
ish
Re NI

TASK 1 : Identifying the battery and type

be @

1 Open the case of computer

Most of the batteries will be like CR2000 etc.
2 Find the battery location on motherboard by referring
o ht

quick guide or manual 6 Identify type of socket (socket with upper tab, socket
with lateral, inside socket laying) provided on battery
t t rig

3 Find the type of cell (example: Coin Cell)

7 Check work sheet by the instructor .
4 Note down information available on cell like voltage,
No py

chemistry, size or package etc

Co

Fig 2

Fig 1

203
TASK 2 : Remove the battery

1 Remove or side the wires laying on battery. 3 Gently pull the battery and remove the battery.
2 Draw back the tabs surrounded by battery by using Fig 4
small screw driver or watch maker screw driver. g

Use suitable watchmaker screw driver for tap

screw lock removing.

Fig 3
Fig 3

ed
bl I
pu M
_______

ish
Re NI

TASK 3 : Replace the battery

1 Identify the polarity of battery by using symbol or indi- Fig 5

be @

Fig 5
cator.
2 Identify the polarity of socket by using symbol or indi-
o ht

cator.
t t rig

3 Place the battery on the socket and press gently to

lock tabs of socket.
No py

4 If it is screw lock tab, hold the lab and make screw the
tab.
Co

5 Check the worksheet to your instructor.

_______

TASK 4 : Identifying RAM (SIMM/DIMM)

1 Open cover of computer system unit using four head 5 Identify the master and slave RAM slots by printed
screw driver. information or by colour or reference manual.
2 Note the mother board information like type of board, 6 Note each RAM slot maximum capacity.
type of RAM (SIMM/DIMM) either it is DDR1 or DDR2
7 Note the RAM slot information like type of RAM sup-
supporting and front system bus speed etc.
porting and RAM Series (1, 2, 3 etc.).
3 Find the RAM location on motherboard by referring
quick guide or manual. Some slots are supporting two or more series.
4 Note the number of RAM slots available on board.

204 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.78

TASK 5: Replace and Extend the RAM

1 Note the fixed RAM information available on board. Fig 1

2 Observe the RAM lock tabs types available on slots.

3 Identify and note the reference notch point of slot.
4 Open the lock tabs gently.
5 Hold the RAM in the proper direction and matching
reference notch.
6 Fix the RAM by pressing gently.
7 Ensure the proper locking of tabs.

_______

ed
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ish
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be @
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No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.78 205

Electronics & Hardware Exercise 1.7.79
Electronic Mechanic - Basic Computer

Test and Replace the SMPS

Objectives : At the end of this exercise you shall be able to
• test the SMPS
• install/replace the SMPS in computer.

Requirements
Tools/Instruments Materials
• Screw driver set - as reqd • SMPS quick installation guide - as reqd
• Anti-static discharge cable - as reqd
• Digital Multimeter - as reqd
Equipments
• Desktop computer system - as reqd
• Extra SMPS of computer - as reqd

PROCEDURE
TASK 1 : Test the SMPS

ed
bl I
pu M
ish
1 Connect main cord to the main socket & discharge 4 Now pick any four wire DISK DRIVE connector of
your body static charge through antistatic discharge SMPS and test red wire with respect to neutral black
Re NI

cable, then open cabinet of CPU Unit using screw wire using digital Multi-meter in DC voltage mode. It
driver. should be +5Volt, if it is OK then measure yellow wire
be @

of this connector with respect to black neutral wire

2 Pick an AT/ATX connector of SMPS and connect it to
using digital Multi-meter in DC voltage mode. It should
mother board in a computer system and switch on
be +12 volt, if it is OK.
o ht

SMPS.
5 If both supplies are OK, means SMPS power supply
3 Check fan of SMPS is working or not if it is ok, SMPS
t t rig

is in working order.
is in working order.
No py

_______

TASK 2 : Install/replace the SMPS

Co

A Removal of old SMPS B Installation / Fixing of SMPS on cabinet of com-

puter
1 Disconnect the power connector from mother board
and record the number of pins and number of con- 6 Fix the SMPS on to rear of cabinet with power socket
nectors in the SMPS connector, if it is single 12 pin and fan facing rear side of cabinet.
burndy connector or two 6 connector then it is a AT
7 Connect the PC power ON/OFF switch in the front
SMPS power supply other-wise if it is 20 pin connec-
panel according to wiring diagram in SMPS cover
tor then it is called ATX SMPS power supply. So ac-
cordingly select compatible correct SMPS to replace 8 Connect mother board power connection from SMPS
AT/ATX power connector as per requirement
2 Disconnect CPU fan connector on motherboard as in
some cases only SMPS provide fan power. 9 Connect different drive power connector to HDD, CD/
DVD drives etc.
3 Disconnect mains ON-OFF switch connections.
9 Get the work checked by the instructor and connect
4 Unscrew SMPS from the cabinet and take out the
regular mains power to switch ON SMPS for a mo-
SMPS unit.
ment and observe fan of SMPS is working or not. If
5 Get the work checked by the instructor. OK, do measure test voltages on drive power con-
nector otherwise troubleshoot SMPS related fault as
guided by the instructor.
10 If found correct voltages, get work checked by your
_ _ _ _ _ _ _instructor & finalize installation of SMPS.
206
Electronics & Hardware Exercise 1.7.80
Electronic Mechanic - Basic Computer

Replace the given DVD and HDD on the system

Objectives : At the end of this exercise you shall be able to
• disassemble the drive cage
• disassemble and assemble HDD
• reassemble the drive cage inside the cabinet.

Requirements
Hardware • Screwdriver set and anti-static
wrist strap - as reqd
• PC with standard configuration - 3 Nos
• Sticking labels (reusable) - as reqd
• CD/DVD drives - 2 Nos
• Anti static covers - as reqd
• HDD drives - 2 Nos

• One PC to be used for demonstration. • The other two identical PC’s to be used by the two
group of trainees.

ed
PROCEDURE
bl I
pu M
ish
Alphabetized steps are for the instructors.
Re NI

Numerical steps are for the trainers.

be @

TASK 1 : To remove the CD/DVD and HDD from the processing unit cabinet chassis.
o ht

At the time of preparation of this exercise practice sheets, • Identifying the snap on springs of drive cage
t t rig

majority of the PC’s have a single drive cage which hosts

• Identify the drive cage guide in the cabinet
all drives. At the time of using this exercise,if situation is
No py

found to be different, the instructor incharge should suitably • Technique involved in pressing the snap on springs
modify the procedure given below. and taking out the drive cage.
Co

A Demonstrate the procedure for removing the drive • Precautions to be taken while handling the drive
cage consisting of at-least one HDD from the computer cage such that other components mounted inside
cabinet. the processing unit does not get damaged.
While demonstrating the following points should be 1 As demonstrated by the instructor, unscrew the fixing
considered; screws and remove the drive cage slowly& gently
without causing damage both to the drives inside the
• Identifying the mounting type and fixtures used.
drive cage and to other components/boards mounted
• Use of correct tools and danger in case of using inside the processing unit.
wrong tools.
2 Get the removed drive cage checked by the instructor.
• Technique involved in removing the front cover of
the processing unit if found necessary.

_______

207
TASK 2 : To remove the drives from the drive cage

A Demonstrate the technique, tips and precautions to be 2 In each of the drives removed from the drive cage,
taken while removing the drives from the drive cage. identify the connectors/ sockets/ jumpers/ switches
While demonstrating, make the trainees understand found at its back/ rear side. Make a rough sketch the
why a drive is positioned in that place and why not at connectors / sockets/ jumpers/ switches and record
a different place in the drive cage. the number of pins and jumpers/ switch settings.
1 As demonstrated by the instructor, remove all the 3 Identify and record the specifications of the drives
drives taking sufficient care that the drives are not given on the drives.
handled roughly, not dropped or damaged while
4 Get the removed drives, identified connectors/ sockets/
removing.
jumpers/ switches and recorded specifications of the
drives checked by the instructor.

_______

TASK 3 : To assemble HDD in to the computer cabinet

A Demonstrate the procedure and technique of B Issue one additional Hard Disk Drive of such a physical
assembling: size that it can be fitted in the drive cage along with the
existing drives.
• HDD into the drive cage.
• Drive cage into the computer cabinet\chassis While Since the intention of asking the trainees to fix
demonstrating the following points should be the second HDD is only to make them practice

ed
highlighted: the skill of mounting the device in the drive

bl I cage, and practice connecting the cable, the

pu M
• Handling the drive cage while fitting the drives
•
ish
Technique in fitting the drives for correct aligment
issued HDD’s may even be a defective drive.
However if the added HDD is a working one,
Re NI

with respect to front panel. then the trainees can be made to learn the skill
• Checking the stability and firmness of the assembly of formatting the second drive, taking image of
be @

the other hard disk and such other very relevant

1 As demonstrated by the instructor, reassemble the tasks.
o ht

drives in the order instructed in the drive cage. During

assembling do not forget to follow the precautions 3 Record the specifications of the second drive to be
t t rig

given to you by the instructor. Take the advice of the fixed on the drive cage. As demonstrated by the
instructor if you are in doubt. instructor, fix the given second HDD with great care
and patience in the drive cage. Make sure that sufficient
No py

2 Get the reassembled drives on the drive cage checked

by instructor for its correctness and stability. space exist between the drives mounted on the drive
cage.
Co

4 Get your work checked by the instructor.

_______

TASK 4: To reassemble the drive cage into the processing unit cabinet/ chassis

A Demonstrate the procedure for reassembling the drive • Any other points specific depending upon the type
cage back inside the cabinet. of cabinet and drive cage.
While demonstrating ensure that stress is made on 1 Slide in the drive cage inside the cabinet as
the following: demonstrated by the instructor.
• Positioning of the cabinet while reassembling the 2 Check if the doors of the CD/DVD drive is in place with
drive cage. the front panel.
• Sliding in the drive cage into the cabinet and locking
Reposition the drive cage if necessary and fix
it in position.
the screw using the correct type of tool.
• Checking the alignment of the CD/DVD drive with
the front panel of the cabinet. 3 Get the reassembled drive cage checked by the
instructor.
• Snap on springs of drive cage .
• Proper fit of the drive cage guide inside the cabinet.
_______
208 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.80
Electronics & Hardware Exercise 1.7.81
Electronic Mechanic - Basic Computer

Dismantle and assemble the desktop computer system

Objectives : At the end of this exercise you shall be able to
• dismantle and assemble desktop computer system.

Requirements
Hardware and software • Screw driver set and Allen key
(depending upon the type of
• Identical PCs with labeled ports,
connection cables fixing used with connectors) - as reqd
(could even be dummy) - as reqd • Sticking labels - as reqd
• I/O devices such as Keyboard, Mouse
Monitor, Printer, Multimedia, Speaker,
CD Drive, DVD Drive and Microphone - as reqd

PROCEDURE
TASK 1 : Dismantle and assemble

1 Switch off and unplug the power chord from the 5 Remove the SMPS connections to Hard Disk drive,

ed
PC-CPU. DVD Drive, Motherboard Main Power, CPU Power,

bl I Fan Power Connector, PSU Connections, inside the

pu M
2 Remove the component connections from the Cabinet

ish
Cabinet.
i.e. USB connections, Keyboard/Mouse Connections,
Re NI
LAN Connection, Parallel and Serial Port 6 Remove the connectors from devices like SATA/IDE
Connections Cables to HDD and DVD, Audio Connectors, Cabinet
Front USB/Audio Connectors.
be @

3 Ensure no power related connection is there with

Cabinet 7 Unscrew the motherboard screws, HDD-DVD
screws and other removable items and dismantle
o ht

4 Unscrew the cover that is opposite to the Mother

all.
board section, as the motherboard section closure
t t rig

is fully closed by motherboard base, and remove

the cover.
No py

Fig 1
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.81 209

 11 Fix the processor and fan, RAM,PCI Cards which
Warning: Do not remove or misplace any
ever removed at proper places.
jumpers placed across the motherboard, as it
will result malfunctioning or dead - error 12 Fix the Harddisk,DVD Drive,Floppy Drive,Other
motherboard operation. components that to be screwed with the cabinet.
13 Connect the connectors from motherboard to
Note : Now the pc totally dismantled.keep a
various devices like SATA,IDE,USB
note of a ll the parts is being dismantled,
Extensions,etc.
which will be easier to re-assemble the
system as in Fig 1 14 Plug the SMPS connections to Motherboard,CPU
PSU,Devices,which are on power required connec-
8 Clean the objects with a soft cotton tions.
cloth,mild blower etc. to remove dust and
15 Screw up the side cover to close the cabinet.
patches on them.
16 Connect the devices and external devices using
Note : Don’t use any water based cleaner connectors into motherboard.
inside the system as it is power condtivetive
17 Connect the power chord finally to the Cabinet.
and may short-circuit in case of moisture.
Keep the parts separated until it is day and
Note: Ensure that all connections are proper
clean.
Now switch ON the power and power-on the
system.
9 Place the SMPS at right position and screw it.
10 Place properly the motherboard on the legs of
cabinet. In case any placement problem place the

ed
motherboard first and screw it before fixing SMPS.
_______
bl I
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ish
Re NI
be @
o ht
t t rig
No py
Co

210 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.81

Electronics & Hardware Exercise 1.7.82
Electronic Mechanic - Basic Computer

Boot the system from Different options

Objectives : At the end of this exercise you shall be able to
• boot the system using Windows operating system
• shut down computer
• change the booting order from HDD to CDROM Drive in BIOS.

Requirement
Equipments/Instruments/Tools
• Desktop PC - as reqd

PROCEDURE
TASK 1 : Boot the system using Windows operating system

1 Once you have made all the connection with PC, • Beep sound been heard when a computer get started.
switch ON your system in the following sequence:
• Keyboard lights flashes.
• AC mains.

ed
• Mouse lights glows.
•
bl I
Stabilizer/CVT/UPS unit (It is recommended to use
pu M
• Monitor lights glows (turn from yellow to green).

ish
a stabilizer/CVT/UPS)
• CD/DVD/Floppy drive lights flashes(turn green).
Re NI
• Power switch of the Distribution box.
• Power on LED and Hard disk LED glows on the CPU
• External peripheral devices such as Printer, Moni-
(turns green).
be @

tor, Speaker, etc.

Printer
2 Press the POWER ON switch on the CPU System.
o ht

• In Dot-matrix / Inkjet (The head moves from right to

• Wait and observe the following.
left and the lights glows).
t t rig

• In Laser jet (clunking sound and the light glows).

No py
Co

Fig 1

American
Megatrends
PC 3200 Single Channel Mode
Checking MURAM
1016 MB OK

Auto-Detecting Pr 1 Slave . . . ATAPI CD-ROM

Auto-Detecting 3rd Slave . . . IDE Hard Disk
Auto- Detecting 4th Master . . . SH-152A C501

Pri Slave : Samsung CD-ROM SH-152A C501

Ultra DMA Mode-2
3rd Slave : ST380215As 3 -AAD
Ultra DMA Mode-5, S.M.A.R.T. Capable and Status OK
4th Master : Hl-DT- STDVD-RAM GI22NS30 1.01
Ultra DMA Mode -5
Auto-detecting USB Mass Storage Device

211
3 Boot process begin and POST operation will Display Fig 3
On the Screen as shown in (Fig 1)

Usually your computer will beep once or twice

on boot up. This is normal, and nothing to
worry about. Repeated beeping combined with
no display and/or error messages indicate that
something might be wrong. Otherwise, your
computer will proceed to perform a power-on
self test.

4 Wait a few seconds after that the system will load

windows OS and display the screen as shown in
(Fig 2).

Fig 2

Hints: Some computer does not have pass-

word. Such case you just press ENTER key for
Skip Password option.

7 Next Desktop screen will come as shown in (Fig 4)

8 Now the system is ready for use

ed
Fig 4

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5 Next Windows start up with asking password for

o ht

enter into Windows as shown in (Fig 3)

6 Type the password correctly (ask the password to
t t rig

your instructor ) then press ‘enter’ key for confirmation.

No py
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_______

TASK 2 : Shut down computer

1 Close all open programs. Fig 5

2 Click ‘ON’ the button and select

shut down Option.

This is turn displays a dialog box with set of

option as in (Fig 5)

3 Move the Cursor over option dialog box and select

"shut down " option and click "Ok" button.

This makes the Windows to close all opened /

running applications if any and shuts down all
activity on the computer so that the power to
computer can be turned off.

212 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.82

4 Wait till screen goes blank. • CPU System
• Power ‘OFF the Distribution box
Although the windows OS closes all running
application and then shuts down the PC , it is • Stabilizer/CVT/UPS unit
not recommended to keep any application
• AC mains
open at the time of turn off the PC.
6 Get your work checked by the instructor.
5 Switch ‘OFF the supply in the following sequence.
• External peripheral devices such as printer, Moni-
tor, Speaker, etc.
_______

TASK 3 : Change the booting order from HDD to CDROM Drive in BIOS

1 First You must start your computer and during the initial Fig 6
booting process display the message shown in
(Fig 6) . Phoenix- AwardBIOS V6.00PG, An Energy Star Ally
Copyright (C) 984-2008, Phoenix Technologies, LTD
2 Press Del or ‘F2’ key on the keyboard to enter in to
CMOS BIOS setup . The BIOS Setup screen Display K98TPV-PLUS-PRO
the startup screen as shown in (Fig 7) Main Processors : AMD Athlogn (tm) XP 3200
CPU Temperature Protection is ON
Entering into CMOS setup by pressing DEL key Memory Testing : 4096000K OK
Memory Clock is 166MGz (DOR333)
is not suitable for all PC. The step for Entering

ed
Detecting IDE Drives
into the CMOS setup depends on the

bl I
motherboard. Press the correct keyboard com-
pu M
ish
mand for entering into setup display on your
computer.
Re NI

3 Select Boot Menu option by moving the arrow keys

be @

on the keyboard and press enter key.

Press DEL to enter SetUp
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06/18/2007-KT440-1523-8E6LY7299C-00
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Fig 7

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.82 213

 • Boot option menu display the options are as shown
To change your Computer device to boot from
in (Fig 8).
first, follow the directions on the BIOS setup
utility screen.
Every BIOS setup utility is different, the spe-
cifics on where the boot order options are lo-
6 Move the arrow key to "Exit" menu and select Exit
cated varies from computer to computer. The
saving changes option ( or Press F10 key on the key-
menu option or configuration item might be
board ) as shown in (Fig 10) will display on the screen.
called Boot Options, Boot, Boot Order, etc. The
boot order option may even be located within Fig 10
a general menu option like Advanced Options,
Advanced BIOS Features, or Other Options.

4 Select removable device option from boot order shown

in (Fig 8).

Fig 8

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• Setup will display the confirmation message on
bl I
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the screen as shown in (Fig 11).

ish
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Fig 11
be @

BIOS will first try to boot from any removable

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devices - like floppy drives or flash drives. If

no removable devices are bootable, BIOS will
t t rig

next try the hard drive, followed by the CD-ROM

drive, and finally the network.
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• Boot order can be changed by pressing the ‘+’and

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‘-’ keys.
5 Set CD ROM drive as a first Boot device and Remov
-able device as a second boot device and hard drive
as a third boot devices as shown in (Fig 9).

Fig 9
7 Select "Yes" by moving arrow key and press ENTER
key on the keyboard for save your CMOS.
Configuration changes and exit form setup.
• Now the computer will restart automatically and
ready to boot from CD ROM drive by display a
message for your confirmation as shown in (Fig
12).
8 Press any key to accept boot from CD ROM drive..
• System loads OS from CD ROM drive and starts
working.
9 Get the work checked by the instructor.

214 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.82

Fig 12

Press any key to boot from CD

_______

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Electronics & Hardware : Electronic Mechanic - Exercise 1.7.82 215

Electronics & Hardware Exercise 1.7.83
Electronic Mechanic - Basic Computer

Install OS in a desktop computer

Objectives : At the end of this exercise you shall be able to
• install windows OS on your PC
• format a secondary hard drive
• install driver software from motherboard CD.

Requirements
Tools/Equipments/Instruments • Operating system CD - 1 No
• A working PC - 1 No

PROCEDURE
TASK 1 : Install windows OS on your PC

Enter into CMOS setup • Once setup begins you see a message stating that
setup is inspecting your computer's hardware
1 Power on PC.
Configuration
Prompt message is displayed as follows • Then windows will copy files and continue to start

ed
Press <DEL> to enter setup setup as shown in Fig 2.

bl I
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2 Press <DEL> key
ish 2
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Immediately you enter into CMOS setup utility

menu.
be @

3 Change the boot sequence by following the steps from

o ht

1 to 8 explained in Task 1 of exercise 1.7.82

4 Insert your windows XP installation disk into CD Rom
t t rig

drive.
No py

The PC will now restart and you should see a

message at the top of your screen telling you
Co

to "Press any key to boot from CD " as shown

in Fig 1

5 Go ahead and Press any key for setup to begin

Next you will see the setup welcome screen as
1 shown in Fig 3
Press Key "R" for repair the existing
corrupted Windows OS. If you to stop
installation press F3 key.

6 Press "ENTER" Key to continue windows setup

process.

Next EULA screen as shown in Fig 4 appear

on the screen

7 Press F8 to accept the Windows XP Licensing

Agreement.
Installation of OS will format your hard disk.
Format will delete all the information stored in If an existing Windows XP installation is
the hard disk. So you should Copy all the im- detected, you are prompted to repair it. To
portant documents before start setup. bypass the repair, press “ENTER” Key.

216
 Fig 3

Fig 4

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• Partition the disk 8 Use the ARROW keys to select an existing partition,
or create a new partition by selecting the non-parti-
All existing partitions and non-partitioned tioned space
spaces are listed for each physical hard disk
as shown in Fig 5 when you want to create a new partition. You
can also press C to create a new partition us-
If you want to create a partition where one or ing non-partitioned space as shown in Fig(6)
more partitions already exist, you must first
If your hard disk is new one then you need to
delete the existing partition or partitions, and
do a partition and format your hard disk.
then create the new partition. You can move
the arrow keys to select an existing partition
9 Press "Enter" key to create the partition.
press D to delete , and then press L (or press
ENTER, and then press L if it is the System To specify the partition size, type the size in
partition) to confirm that you want to delete the megabytes (MB) for the new partition.
partition. Repeat this step for each existing
partition that you want to include in the new 10 Repeat steps 8 to 9 to create additional partition.
partition. When all the partitions are deleted,
select the remaining non-partitioned space, and
then press C to create the new partition.

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.83 217

Fig 5

Fig 6

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OS starts partitioning your total hard disk

memory space into 2 or 3 partition as allotted
by you as shown in Fig 7.

Fig 7

218 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.83

11 Press the Arrow keys to select the partition where
The next screen shown in Fig 8 lets you to
you want to install Windows XP, and then press
choose the file system you want to reformat
ENTER.
your hard drive.

Fig 8

ed
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12 Select the format option by moving the arrow keys
pu M
and press "ENTER":
ish
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Format process shown in Fig 9 will come

on the screen.
be @

Fig 9
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Setup program will now format the partition Next screen showing that your computer
drive and copy the files followed by a restart will restart in 1 minutes.
as shown in Fig 10.
Computer restart with windows XP screen
as shown in Fig 11.
Do not press any key to boot at this point
13 Setup will now ask you to select your language

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.83 219

 Fig 10

Fig 11

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14 Move the cursor to US and English click "Next " Tab 15 Select "Next" tab to continue installation.
Enter your name and organization appear on the 16 Type product ID code on the next screen shown in
screen as shown in Fig 12. Fig 13.

12 13

220 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.83

 Product ID code is available on the side of the 14
computer Tower or CD cover

17 Enter Name of your computer , Administrator

password and confirm the password by retyping the
password again asked in the next screen as shown
in Fig 14

You are not interested to give password then

just press "Enter" key to skip the Step.

18 Click "Next " Tab to go to Time zone screen as shown

in Fig 15

Fig 15

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19 Set month, date, time and Click "Next" tab. 16

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Wait for the Next your Network settings screen

appear on the screen as shown in Fig 16

20 Click "Next" tab to finish installation.

Computer restart with Windows XP OS fol-

lowed by Desktop screen.

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.83 221

TASK 2 : Format a secondary Hard drive
17
1 Click on icon and click mouse right button it will dis-
play a popup menu as shown Fig 17
2 Click "Open"option.

A screen will display as shown in Fig 18.

3 Select the "D" drive and right click the mouse will
display a popup menu as shown in Fig 18.
4 Select "Format" option.

A screen will display on the screen.

5 Select "NTFS" and Click "Ok" button.

Fig 18

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_______

TASK 3 : Install Driver software from motherboard CD

1 Insert Motherboard CD into CDROM Drive.

Motherboard CD contains all the driver soft-
2 Follow the instructions shown on your screen to in- ware to activate all Hardware components as-
stall sound driver, Network driver etc., sembled in motherboard.
3 System will restart after every driver files are copied
to your system to activate the hardware. 4 Check the work checked by your instructor.

_______

222 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.83

Electronics & Hardware Exercise 1.7.84
Electronic Mechanic - Basic Computer

Install a Printer driver software and test for print outs

Objectives : At the end of this exercise you shall be able to
• install a printer on Windows
• perform self test on printer
• manage print queue.

Requirements
Tools/Equipments/Instruments
• A working PC - 1 No
• Printer with driver CD - 1 No

If you have a laser printer, allow a few inches Install printer driver software according to the
of space on all sides for ventilation manufacturer's instructions given in the CD.

PROCEDURE
TASK 1 : Install a Deskjet 6500 series Printer on Windows.

ed
bl I
pu M
1 Connect the power cable to the AC mains.

ish
2 Connect the data cable to the suitable port.
4 Click on the button found at the left
Re NI
corner of the taskbar.
3 Switch on the printer and system.
On clicking the start button, a menu list pops
be @

ups as shown in Fig 1.

o ht

Fig 1
t t rig
No py
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223
6 Take the cursor over and
double click a screen will appear as shown in Fig 2

Fig 2

ed
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be @

7 Click the right mouse button. The following popup 8 Move the cursor over "Add printer" and double click
menu will appear as shown in Fig 3. the mouse. The Following wizard will appear as shown
o ht

in Fig 4.
t t rig

Fig 3
9 Click "Next " tab in the Add Printer wizard .
10 Local or Network printer wizard as shown in Fig 5 will
No py

appear on the screen.

Co

224 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.84

 Fig 4

ed
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Fig 5
ish
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be @
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11 Select "Automatically Detect and Install My Plug and 13 Click "Next" Tab .
Play Printer option and then click "Next" tab
14 Select printer port wizard which appears on the screen
12 Now the computer will try to automatically detect and as shown in (Fig 7).
install printer driver software . The computer not able
15 Create a new port for your printer or select the default
to detect the software then it will display the Next
printer port given in the Wizard.
wizard as shown in Fig 6.

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.84 225

 Fig 6

ed
Fig 7
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16 Next Install printer software wizards appeared on the 19 Give name of your printer asked in the name printer
screen as shown in (Fig 8) with printer Manufacture's wizard.
name and model of the printer.
20 Select "Yes" to set install printer as a default printer to
17 Look for your printer in the list. your computer.
18 From the list if you find your printer then click "Next" 21 Click "Next" tab.
and proceed to the "Install Your Printer Driver" wizard
shown in Fig 9.

226 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.84

 Fig 8

ed
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Fig 9

ish Fig 10
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be @
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Print test page wizard will appear as in Fig 10.

24 Installation process will complete and a Wizard will
22 Select " Yes" to print a test page.(if you don't want to appear on the Screen as in Fig 11.
print then select "No") 25 Click " Finish" tab
23 Click "Next" tab.
Printer will print the test page .

26 Get the work checked by the instructor.

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.84 227

Fig 11

If Printer Driver Not Listed?

Next wizard shown in Fig 12 will display on the
1 Click "Have disk" tab on Install printer software wizard. screen.

ed
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ish
Fig 12
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Fig 13
2 Insert the printer driver CD into CDROM drive given
by the manufacturer.
3 Click and select CDROM drive
4 Locate the setup file from CDROM drive
5 Click "OK "tab.

Next wizard shown in Fig 13 will display on

the screen.

6 Move the mouse to the printer name and Click .

7 Click "Next" tab.

Printer Connection Wiard as shown in Fig 14

will display on the screen.

228 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.84

 Fig 14

8 Select the type of connection and click "Next" tab. Now software license agreement wizard shown
in Fig 15 display on the screen.

ed
Fig 15
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9 Accept the licence by click the option . 12 Click " Next" tab
10 Click "Next" tab. 13 Click "Install " tab from the wizard shown in Fig 16.
11 Select the Printer connector type from the Connector
Type Wizard .

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.84 229

 Fig 16

Now the Computer will start copy driver soft-

ware from CD as shown in Fig 17.

Fig 17

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Fig 18
Next wizard shown in Fig 18 will display on
the screen.

14 Select Print a test page option and click "Finish" tab.

Completing the Add printer Wizard will dispay

on the screen (Fig 11).

15 Click " Finish " Tab.

16 Test Print page will print on the paper.
17 Show the test page to the instructor.

230 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.84

TASK 2 : Perform a Self - Test on Printer
1 Turn on your computer and printer. 6 Click "Print Test Page" to start the self-test.
2 Click" start" on your Windows taskbar.
Perform a self-test each time you install a new
3 Choose "Control Panel" then ink cartridge, or when your print quality is low.
The self-test will not work well if the printer ink
levels are low.
4 Click" View Installed Printers".
5 Right click on the installed printer icon.
_______

TASK 3 : Manage Print Queue

To Pause printing
1 Open Microsoft Word and Open an existing document.
2 Print the document using print command. 4 Select the print job in the list which you want to pause,
5 Click Document menu in the dialogue box (a pull-down
After issuing Print command a printer icon will
menu will be displayed) and click on Pause command
be displayed in the system tray as shown in
as shown in Fig 21 .
the Fig 19.
Fig 21
Fig 19

ed
bl I
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Printer icon
ish
Re NI

3 Move the mouse cursor over the printer icon displayed

be @

in the system tray and Double click on it.

A Printer dialogue box will be displayed as

o ht

The printing process will be paused.

shown in the Fig 20. In that dialogue box the
t t rig

list of print job(s) and its software and status , 6 Repeat the previous step and select Restart to restart
owner and number of pages, port time and date the printing process.
(when it was started) and its size will be dis-
No py

played. Also the name of port in which the job To Cancel printing process
is being printed.
Co

7 Select the print job in the list which you want to cancel
printing,
Fig 20
8 Click Document menu in the dialogue box (a pull-down
menu will be displayed) and click on Cancel command
as shown in Fig 21 .
The printing process will be cancelled

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.84 231

Electronics & Hardware Exercise 1.7.85
Electronic Mechanic - Basic Computer

Install antivirus software, scan the system and explore the options in the
antivirus software
Objectives : At the end of this exercise you shall be able to
• install antivirus software from a disc
• install antivirus software from internet
• scan the system for virus.

Requirement
Tools/Equipments/Instruments
• Computer or Laptop with
Windows operating system - as reqd
• CD of antivirus software - as reqd

PROCEDURE
TASK 1 : Install antivirus software from a Disc

1 Load the anti-virus CD-ROM into your disc tray and 2 Type in the product security code in the boxes on your

ed
close, then wait for the CD menu to appear on screen. screen.
bl I
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ish
Step 1: Click the "Install Now" button
The security code is printed on the back of the
plastic case for the CD-ROM containing your
Re NI
This should be located in the lower left hand corner of
the web site. Clicking this button begins the process. anti-virus software.
be @

Step 2: Download the required files

3 Follow the on-screen prompts, clicking "Yes" when
After you click the "Install Now" button, the required files asked, "Do you wish to install this software?"
o ht

will automatically download to your computer.

4 Reboot your computer when the installation is com-
plete.
t t rig

This involves shutting down and restarting the computer

No py

so the anti-virus settings can take effect.

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TASK 2 : Install Antivirus Software From the Internet

1 Go to an anti-virus software company site on the Some offer trial versions of anti-virus programs for
Internet to purchase an anti - virus program. free.
2 Choose the software product you wish to purchase
from the company’s menu of offerings and click “Buy
Now” or Download Now”.

_______
232
 3 Enter your credit and other personal information in
the required fields to purchase the software,then press
“Enter”.
4 Follow the on-screen prompts, clicking "Yes" when
asked if you wish to download the software to your
computer.

ed
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Electronics & Hardware : Electronic Mechanic - Exercise 1.7.85 233

 ed
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5 Wait for the download to complete.

This could take several minutes, depending on

the speed of your Internet connection. Do not
log off the computer or change any setting until
the software has finished downloading to your
system.

234 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.85

6 Reboot your computer if prompted at the end of the
download.

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Electronics & Hardware : Electronic Mechanic - Exercise 1.7.85 235

7 Get the work checked by the Instructor
_______

ed
TASK 3 : Scan the system for virus

bl I
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ish
1 Go and select the anti-virus software from the start 4 Observe and study the status report of software
menu.
Re NI
5 Observe the virus and warning shown by the software
2 Find the system SCAN button on software screen
be @

3 Click the button for scan

o ht

_______
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236 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.85

Electronics & Hardware Exercise 1.7.86
Electronic Mechanic - Basic Computer

Install MS office software

Objectives : At the end of this exercise you shall be able to
• know the procedure of installation of MS office software.

Requirement
Tools/Equipments/Instruments
• Desktop Computer or Laptop - as reqd
• CD/DVD of MS OFFICE
software - as reqd

PROCEDURE
1 Insert the MS office Enterprise CD/DVD. If the setup Fig 1
wizard does not automatically begin then click start >
Run>D:\setup.exe
2 The product key from the back of the CD/DVD jacket.
Note: This is unique code. Please keep in a safe place!

ed
Click continue (Fig 1)
bl I
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ish
3 Check the box "I accept the terms of this agreement"
and click the continue button (Fig 2)
Re NI

4 Choose an installation option, upgrade (removes of-

fice installed previously (lower version 2013,2017 etc.))
be @

or customize (keeps office of earlier installed version

and the latest currently installed version)
o ht

Outlook 2003 will be uninstalled in either op-

t t rig

tion. Outlook will be updated and your settings

and mail will migrate to the new version.
No py
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Fig 2

237
If you click upgrade, go on to step 5 (Fig 3)
If you click customize, go on to step 4a (Fig 3)

Fig 3

4a Click the radio button for "keep all previous versions" Fig 5
(Fig 4)
Fig 4

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5 Click the installation Options tab, left-click the first drop

down box and click Run all from My Computer (Fig
Fig 6
5)
6 Click Install now (Fig 5).
7 Installation will begin. It may take 15-30 minutes to
finish (Fig 6).

238 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.86

8 Click Close to complete the installation (Fig 7) 9 The first time you launch any office program, you will
be prompted to activate the software. As long as you
Fig 7 have an active Internet Connection, choose the de-
fault option and click Next. (Fig 8)

Fig 8

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10 When the activation finishes, click Close (Fig 9). Fig 10

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11 Click OK to finish (Fig 10)

Fig 9

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.86 239

Electronics & Hardware Exercise 1.7.87
Electronic Mechanic - Basic Computer

Create folder and files, draw pictures using paint

Objectives : At the end of this exercise you shall be able to
• create document file in windows explorer
• create folder in windows explorer
• open paint brush and new drawing
• draw different types of lines
• identify and work with paint brush tools
• save clippings to disk.

Requirement
Tools/Equipments/Instruments
• Desktop Computer or Laptop
with windows OS, MS-Office - 1 No

PROCEDURE
TASK 1 : Creating Document file in windows Explorer

ed
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1 Click start button in task bar and click “Computer”
program list or press
ish
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windows key + E in the key board

be @

1
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The windows explorer window will appear as on Fig 2.

240
 Fig 2

2 Select and double click the LocalDisk (D:), already

created files and folders are displayed as on Fig 3.

ed
3 Right click on “D:” drive.

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Fig 3

ish
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4 Select “New” Option and click Microsoft Word

Document” as on Fig 4.

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.87 241

 Fig 4

The New Microsoft Document file as shown

in Fig 5.

ed
Fig 5
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5 Delete the “New Microsoft Document”

6 Type any file name as you like for eg: Sample and
press Enter key as on Fig 6.

242 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.87

 Fig 6

7 Double click the “Sample” file , type any text and

save the file.

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Fig 7

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8 Get it check with your Instructor

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.87 243

TASK 2 : Creating folder in Windows Explorer

1 Follow the steps 1 and 2 in Task 1.

2 Right click and select New option and click “Folder”

as on Fig 8
Fig 8

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The New folder created as shown in Fig 9
be @

Fig 9
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3 Type any “Folder Name” as you like for Eg:

Electronic Mechanic as on Fig 10.

244 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.87

 Fig 10

4 Press Enter Key

_______

ed
TASK 3 : Start a Paintbrush and new drawing

bl I
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Start a Paintbrush: 1 Choose File
Re NI
1 Open Accessories in Windows 2 Choose Open
2 Choose Paintbrush Color or Black & White
be @

Begin New Drawing: 1 Choose Options.

1 Choose File 2 Choose Image Attributes.
o ht

2 Choose New 3 Choosing Black and White will give pattern fill options.
t t rig

Choosing Color will give color fill options.

Loading a Drawing:
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_______
Co

TASK 4 : Draw a line

3. Fill color is the same as foreground color.

Draw a Straight Line:
Draw a Freehand Line:
1 Choose
2 Drag and release to complete.

That the color used by the brush is set by the 1 Choose the paintbrush icon.
foreground color below. Point at the desired 2 The brush shape can be that of a dot, a rectangle or a
color in the Palette below and use the left line.
mouse button to set the color or the line before
3 Change the shape of the brush with the Brush Shapes
staring to draw the line.
option under Options.
Line Color:
The size of the brush is set by the line thickness
1 Line tools will use the foreground color (or pattern if in tool in the lower left of the screen. Also note
black and white) as selected from the Palette below that the paint used by the brush is set by the
with the left mouse button. foreground color below. Use the left mouse
2 Lines around circles, rectangles, polygons, etc. will button to set the color or the line.
use the background color as selected from the Palette
below with the right mouse button. _______
Electronics & Hardware : Electronic Mechanic - Exercise 1.7.87 245
TASK 5: Work with Paintbrush tools

Circle/Ellipse Tool: 2 Erases both foreground and background to white.

Spray Paint (Air Brush):

1 Choose with the left mouse button. (Holding 1 Choose the icon. Hold down the left mouse

down shift while placing points forces a circle) button to spray.

2 Place corner point (of an imaginary box around the 2 Note the paint used by the sprayer is set by the color
circle) and press the left button. below.
3 Drag to opposite corner point and release. 3 The width of the spray pattern is set by the line
thickness below.
Box Tool:
Move Objects or Areas:

1 Choose with the left mouse button.(Holding

1 Outline the area with irregular or rectangular
down shift while placing points forces a square)
2 Use left mouse button for one corner. Drag to opposite
corner point and release. scissors icon. Use the left mouse button and
Draw a Splined Line: drag.
2 To move, point to the center of the outlined area and

ed
1 Choose drag.

bl I
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2 Click on line start. Drag to end.
ish If you use the left mouse button to move the
area, the background colors or patterns will
Re NI

3 Click to one side of the line and drag to stretch line into
become transparent. If you drag with the right
a spline.
mouse button, both the foreground and
be @

4 Repeat (3) for second stretch. background colors are retained and moved
Zooming In: together
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It is possible to modify a painting pixel by pixel. Fill an Area:

t t rig

1. Choose View.
2. Choose Zoom In. 1. Choose the paint roller Set the fill type by
No py

3. Select the zoom area. clicking on the color or pattern along the bottom of the
Co

4. Click on pixels to change them to the foreground color. screen.

Zooming Out: 2. Move icon until the point of the paint roller shadow is
in the area to fill, and click. (If too much area is filled,
1. Choose View menu. use the Undo under the Edit menu).
2. Choose Zoom Out. Other Modifications:
Line thickness: Once a cutout has been defined, it may be modified with
Pick options: rescaled with Shrink and Grow,

Point and Click on icon with the left mouse skewed with Tilt, flipped with Flip
Vertical and Flip
button.
Horizontal or changed dark to light with Inverse, and
Erasing:
made inverse (negative image) by using the options in the
Pick menu.
Choose 1) or 2) icon with the left button.

1 Erases the foreground color only and replaces it with

background.
_______

246 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.87

TASK 6: Save Clippings to Disk

Mistakes:
1. Outline the area with irregular or rectangular
Before doing anything else, choose Edit and
Undo, as this undoes only the last process. You
can also Press Esc to stop most processes.
scissors .
Calligraphy:
2 Choose Edit and Copy to put it on the clipboard (or)
choose Edit and Copy to save the clipping under
several different bitmap options. This is useful for Choose the icon. Change the shape of the brush
preparing graphics for other programs because only
with the Brush Shapes option under Options. Also, the
the selected area is saved, minimizing the file size.
line thickness must be set greater than minimum. Note
Text: that the paint used by the brush is set by the foreground
color or fill pattern below.
1 Choose Use the Full Screen:
Choose View. Choose View Picture. <Esc> to get back.
2 Point to start location with left button.
Saving:
3 Type, Return key is carriage return.
1. Open File menu with left mouse button.
Change font Style and Size before choosing another tool.
2. Select Save as ...

ed
Quitting:
bl I
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1. Choose File

ish 2. Choose Exit

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_______
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Electronics & Hardware : Electronic Mechanic - Exercise 1.7.87 247

Electronics & Hardware Exercise 1.7.88
Electronic Mechanic - Basic Computer

Explore different menu/tool/format/status bars of MS word and practice the

options
Objectives : At the end of this exercise you shall be able to
• create a word document and identify its components
• create resume
• format the document using tools
• insert picture and clip art, word art.

Requirement
Tools/Equipments/Instruments
• Desktop Computer or Laptop
with windows OS and MS office - as reqd
Software
• Installation MS office Software - as reqd

PROCEDURE
TASK 1 : Create a word document and identify its components

ed
1 Open a new word document as in Fig
bl I
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2 Identify the various screen components as in
ish
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below Fig
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No py

_______
TASK 2 : Create a Resume of a Candidate
Co

1 Type the following in the document. Qualification :

Degree : B.Com, Completed in National College,
RESUME
KCR, Karnataka, 2014 PGDiploma : PGDCA,
Name : G.Raghavan Completed in Manipal Institute, Sadasiva Nagar,
Date of Birth : 17.08.1994 Bangalore. PGDPMIR , Completed in Manipal
Institute, Sadasiva Nagar, Bangalore.
Gender : Male Experience : 2 Years as Assistant Manager @
Father Name :R.Gnaneshwar Shiv Hundai, JT Nagar, Bangalore.
Languages Known : Kannada, English, Hindi,
Religion : Hindu
Telugu
Nationality : Indian
Hobbies : Social Networking, Marketing studies
Category : General
Declaration :
Address : No.12/38, Nageswar II Cross, III Phase,
Harikrishna Apts., Chandan Circle, All the above said information are true and fair
Malleswaram, Bangalore. to the best of my knowledge

Mobile : 09833156987 Station : Bangalore

Sincerely yours,
Email :raghavan_009@gmail.com
Date :
_______
248
TASK 3 : Format the document using tools

1 Select the title ‘Resume’ and center it using Center

Note : Font and formatting options are
Align Tool in the Paragraph block
available in the main ribbon as in fig shown.

2 Make it Bold using Bold option below the Font tab. 6 Set the alignment for Degree and others with
proper TAB values.
3 Align the name, ‘:’ and name of the candidate
with TAB as like below 7 Make uniform for experience, Languages and
Hobbies also.
Name : G.Raghavan
8 Make the Declaration into the center alignment
4 Align other lines with ‘:’ according the above line
and bold.
to make it uniform aligned upto email.

ed
9 Make the declaration text center aligned.
5 Make it Bold and underlined the Qualification
and Experience titles.
bl I Note : The document view will be as below after
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ish alignment is over.
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Electronics & Hardware : Electronic Mechanic - Exercise 1.7.88 249

 RESUME
Name : G.Raghavan
Date of Birth : 17.08.1994
Gender : Male
Father Name : R.Gnaneshwar
Religion : Hindu
Nationality : Indian
Category : General
Address : No.12/38, Nageswar II Cross, III Phase,
Harikrishna Apts., Chandan Circle,

Malleswaram, Bangalore.

Mobile : 09833156987

Email : raghavan_009@gmail.com

ed
Qualification :

bl I
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ish
Degree : B.Com, Completed in National College, KCR, Karnataka, 2014
PGDiploma : PGDCA, Completed in Manipal Institute, Sadasiva Nagar, Bangalore.
Re NI

PGDPMIR , Completed in Manipal Institute, Sadasiva Nagar, Bangalore.

be @

Experience : 2 Years as Assistant Manager @ Shiv Hundai, JT Nagar, Bangalore.

o ht

Languages Known : Kannada, English, Hindi, Telugu

t t rig

Hobbies : Social Networking, Marketing studies

No py

Declaration

All the above said information are true and fair to the best of my knowledge
Co

Station : Bangalore Sincerely yours,

Date :

10 Save the document for reference.

_______

TASK 4 : Insert picture and clipart, wordart

1 Create a Text box on the right top corner of the

resume using Insert->Textbox as in Fig 1

250 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.88

 Fig 1

2 Insert picture of the applicant using Insert->Picture

option into the text box as in Fig 2.

Fig 2

ed
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ish
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3 Select the text box and remove its outline by double

Click on the text box, Drawing Tool->Shape Outline
Co

to NO OUTLINE as in Fig 3.

Fig 3

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.88 251

 4 Select Resume and make it as word art using
Insert->Word as in Fig 4 and apply a style to get
the word Resume to appear in a stylish
appearance.

Fig 4

ed
bl I
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ish
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5 The final appearance of the title may be as in Fig 5
be @

Fig 5
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Note : If misalignment occurs while making

title design, do delete the title and insert a
new word art to make the title as Resume.

_______

252 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.88

Electronics & Hardware Exercise 1.7.89
Electronic Mechanic - Basic Computer

Explore different menu/tools/format/status bars of Ms excel and practice the

options
Objectives : At the end of this exercise you shall be able to
• create excel file
• create model marksheet
• use simple formula for calculations
• formatting worksheet.

Requirements
Tools/Equipments/Instruments
• Desktop computer (or) Laptop
with MS office - 1 No

PROCEDURE
TASK 1 : Create and Excel file and identify its components
1 Open Microsoft Excel start menu

ed
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ish
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2 Find the screen elements and its names

3 Save the file as ‘myexcefile.xlsx’

253
Task 2 : Create a model marksheet of students

1 Set cursor point to cell A1

2 Type the tiles of the marksheet columns as below:

A1 : Sl. No., B1 : Name of Student, C1 : Class. D1 : Language, E1 : English, F 1 : Maths, G1 : Science, H1 : Social
Science, I1 : CCE, J1 : Total, K1 : Average, L1: Status
3 Create Students List as below table :

Sl. Name of Class Lan Eng Maths Science S Science CCE Total Average Status
No Student

1 Nagaraj VII 58 70 98 88 67 70 451 75%

2 Manjunath VII 70 70 88 76 55 80 439 73%

3 Sabir Ali VII 58 85 99 94 73 92 501 84%

4 Albert VII 82 85 89 81 84 68 489 82%

5 Raju VII 33 42 60 31 55 60 281 47%

Note : The excel sheet cells are not auto

adjusted. Use the Ribbon->Format->Autofit

ed
Column Width to make the contents of the
bl I
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columns to fit accordingly as in Fig.

ish
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4 Save the file for future use.

TASK 3 : Using simple formula for calculations

1 Open the saved Excel file. 4 Select the Formula cell and place the mouse cursor
at the right bottom of the cell to drag+copy to other
2 Select the cell J2, which requires a total of marks.
cells.
3 Enter the formula for sum of the mark values as
5 Drag the point up to the cell J6 to copy the formula
‘=SUM(D2:H2)’, which calculates the sum for cells
for the following cells.
from

D2 to H2, i.e. 381.

254 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.89

6 Calculate average from the total and no. of
subjects with the formula ‘=AVERAGE(D2:H2)’

7. Set roundoff value for average using formula

‘=ROUND(AVERAGE(D2:H2),0)’

8 Drag the formula to next following cells.

ed
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ish
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9 Obtain result of the student as mark should be

higher than 35 in all subjects using the formula as:
‘ =IF(AND((D2>34),(E2>34),(F2>34),(G2>34),(H2>34),(I2>34)),”PASS”,”FAIL”) ‘

Note : IF is a logical condition which could

generate result based on condition and pass
success or failure value to the cell. AND logic
makes the following conditions are true in
whole. The results value to be in success it is
PASS and in failure its FAIL.

10 Drag the status / result cell to the following cells

also.

11 The final sheet will be as in Fig.

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.89 255

12 Save the file for reference and refer instructor for
formula related issues.

Task 4 : Formatting worksheet, cell and create a chart/graph

ed
1 Open the saved file for reworking.

bl I
2 Set the Sl.No. column to contain numbers as select
pu M
ish
the cells in A2 to A6 and right click-> Format Cells
Re NI
and select as Number with no decimal points
required as in Fig.
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3 Set the Name column to contain Text and like other

columns also.
4 Select cells A1 to L6 and in the border setting select
lines for all as in Fig. to make all cells are with border.

256 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.89

 ed
bl I
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5 Select the row 6 as it contains the result as FAIL and

ish
to differentiate with color, use FILL tool below Font
Re NI
tool and select the color to fill in the cells as in Fig.
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6 Save the file to print.

7 Click File menu and Print option to print the sheet as
in Fig.

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.89 257

 ed
bl I
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ish
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8 Choose Sheet 2 to create different Worksheet, and it

o ht

can be added any number of sheets within a single

WorkBook.
t t rig

9 Save the file and exit.

No py

10 Refer instructor for more queries.

Co

_______

258 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.89

Electronics & Hardware Exercise 1.7.90
Electronic Mechanic - Basic Computer

Prepare power point presentation on any three known topics with various
design, animation and visual effects
Objectives : At the end of this exercise you shall be able to
• open MS power point
• identify screen component
• create presentation
• add slides and insert pictures
• add audio and video elements
• add animation objects
• make slide show.

Requirements
Tools/Equipments/Instruments
• Desktop computer (or) Laptop - 1 No
Software
• CD of MS office - as reqd

ed
PROCEDURE
bl I
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TASK 1 : Open MS Powerpoint 2010
ish
Re NI

1 Go to start and select MS Powerpoint 2010 to

open as shown in Fig 1 below
be @

Fig 1
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2 View the default powerpoint file as in Fig 2

259
Fig 2

ed
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ish
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3 Save the blank new file as test.pptx and exit.

_______
be @

TASK 2 : Identify the screen components

o ht

1 Open the saved test.pptx and find the components

t t rig

as per the following Fig 3 and table

No py

Fig 3
Co

260 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.90

Components table :

1 File Menu

2 Quick Start Menu

3 Ribbon

4 Ribbon Top Menu

5 Help

6 Slide Sorter / Outline View

7 Slide View

8 Notification Bar

9 Status Bar with Common Tools

_______
TASK 3 : Select a layout and create the first presentation

1 Click on File Menu and select New option.Layout

ed
contains many items as in Fig. 4

bl I
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Fig 4

ish
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2 Click on Blank presentation to create a blank

presentation.
3 Type the title as ‘MY PRESENTATION’
4 Type the sub title as ‘Presented by : ‘ and your
name as in Fig 5

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.90 261

Fig 5

ed
bl I
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ish
5 Set the background of the slide by right click on
Re NI

screen,format background,Fill-> a pattern to set the

background as in Fig 6
be @

Fig 6
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6 Save the file as ‘mypresentation.pptx’ and close.

262 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.90

TASK 4 : Adding slides and inserting pictures

1 Open the saved ‘mypresentation. pptx’ file. Fig 9

2 Select Insert picture in the ribbon and select from
‘Sample Pictures’ folder a picture to Insert into the
slide show.
3 Transform the picture ends to resize to fit the place
and place it at the top of the slide as in Fig 7
Fig 7

6 Insert a picture in the slide using my pictures folder

ed
or any folder which picture to be placed.
bl I
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ish
7 Add a caption for the picture as in Fig 10
Re NI
Fig 10
be @

4 Click on Arrange option and select ‘send to back’ to

make it behind the text as in Fig 8
o ht

Fig 8
t t rig
No py
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8 Save the presentation.

5 Insert a new slide using Home->Insert New Slide->

Select an option for slide as in Fig 9

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.90 263

TASK 5 : Adding audio and video elements

1 Open the saved powerpoint file. Fig 12

2 Inset a new slde after slide 2.
3 Insert a video file usig Insert -> a video from Sample
videos folder as in Fig 11
Fig 11

4 Play and confirm the video for presenting

5 Insert audio file using Insert -> Audio -> audio from
musinc folder like mp3 audio as in Fig 12

Note: Power point allows for live audio 6 Save the file for making the powerpoint show.

ed
recording which can be added as voiceover
bl I
the slide. For the purpose,a mic is required
pu M
with the desktop.
ish
Re NI

_______

TASK 6 : Adding animation on objects,text and slide transitions

be @

1 Open the saved ‘mypresentation.pptx’ for setting up

o ht

Note : The numbers appear near the items

animation.
show the order of animation. If required,it
t t rig

2 Select slide 1 Title (My presentation) and add can be altered.

animation using Animation Menu and apply an
No py

effect desired to get a preview of the animation. 4 Add animation for slide 2 also.
3 Select Subtitle,picture and add animations as in 5 Set the timing of animation for slide 3 contents
Co

Fig 13 using Animation pane -> Click on the instance

(object name) and start with previous as in Fig 14
Fig 13
Fig 14

264 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.90

 6 Arrange the animation for all the objects using
Note : Start with previous makes automatic
Animation Pane,to playback automatically.
playback of the object animation after the
previous one is finished. If selected Start on 7 Set the Transition for slides,enabling it to play
Click requires a mouse click or a spacebar automatically after loading of every slide using
press on every animation to start. Transition menu as in Fig 15

Fig 15

8 De - Select the tick on Advance Slide - On Mouse

Click to enable automatic advancing of slides on
play back.
9 Set time after 00.05to start next slide time click on
Apply to All to make it for all the slides.
10 Save the file for final playback.
_______

TASK 7: Making a slideshow

ed
1 Open the file for making the slide show. 3 Select video file in slide 3 and in the Animation

bl I pane,effect options in the dropdown,select Timing

pu M
2 Set the animations created eariler to ‘start after

ish
previous’using Animation pane in the Animations
as Animate as part of the sequence to play the
Re NI
video automatically on loading. Do the same for the
menu.
audio file as in Fig 16.
be @

Fig 16
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4 Click slideshow,setup slideshow option to bring the Fig 17

Set up Show window as in Fig 17.

Note : In the setup show, default of

presented by a speaker makes the show to
view in full screen. Tick the ‘Loop
continuously until Esc’ option for
continuous playaback of slide show. In this
case,the animations are pre- set with play
back options,so no other changes required.

5 Set choices and press OK.

6 Save the file before play the animation.

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.90 265

7 Click on the From beginning option to view the slide
show from beginning of the first slide,or use F5 key
to start the slideshow.
8 Save the file and exit.
9 Refer instructor for more options.

_______

ed
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266 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.90

Electronics & Hardware Exercise 1.7.91
Electronic Mechanic - Basic Computer

Convert the given PDF File into Word file using suitable software
Objectives: At the end of this exercise you shall be able to
• Convert PDF file into word file.

Requirement
Tools/Equipments/Instruments
• Desktop Computer or Laptop - 1 No
Software
• Software PDF to word
converter - as reqd

PROCEDURE
TASK 1 : Converting PDF file into Word file
1 Click start button in desktop window
2 Select Easy PDF to Word converter in the program
list

ed
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3 Click Easy PDF to Word converter as on Fig 1.
pu M
ish
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Fig 1
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267
 The PDF to Word converter window appear as shown in Fig 2.

Fig 2

ed
4 Click file menu and click open menu item in the
window as on Fig 3.
bl I
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Fig 3
ish
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The open dialog window will display as on

Fig 4, in the dialog box select any low size
PDF file and press open button,suddenly the
save dialog box also will appear.

268 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.91

Fig 4

5 Type the file name and click save any drive as

shown in Fig 5.
Fig 5

ed
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After converting to PDF file, the warning

message will display as shown in Fig 6.

Fig 6

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.91 269

Electronics & Hardware Exercise 1.7.92
Electronic Mechanic - Basic Computer

Browse search engines, create email accounts, practice sending and re-
ceiving of mails and configuration of email clients
Objectives: At the end of this exercise you shall be able to
• open yahoo website
• open google website
• open dictionary website
• download the image
• download software
• create mail account
• open the mail account
• compose mail
• check the inbox.

Requirement
Tools/Equipments/Instruments
• Desktop Computer or Laptop
with windows OS - 1 No

ed
• Internet Connection

bl I
pu M
PROCEDURE
ish
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TASK 1 : Open the Yahoo Website

be @

1 Boot the system, if not booted. 5 Select Programs as in Fig 2.

2 Check the internet connection.
o ht

Fig 2
3 Double click the internet explorer on the desktop or
t t rig

4 Choose Start button as in Fig 1.

No py

Fig 1
Co

270
6 Click Internet Explorer Fig 3
7 Opened internet explorer window
8 Type the website address : www.yahoo.com on
address bar as in Fig 3.
9 Displayed yahoo web site.

_______

TASK 2 : Open the Google

1 Type the address : www.google.com on address bar Fig 4
as in Fig 4
2 Displayed google website

ed
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_______
TASK 3 : Open Dictionary.com website

1 Type the address : www.dictionary.com on address Fig 5

bar as in Fig 5
2 Displayed dictionary website

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92 271

TASK 4 : Download a Picture

1 Type the address : www.google.com on address bar 10 Choose saving location

as in Fig 6.
11 Click Save button
2 Type the word "Flowers" on text box.
Download Child Image
Fig 6 12 Type the address www.yahoo.com on internet explorer
address bar
13 Displayed yahoo website
14 Type the word child Image on text box and click search
tab
15 Choose images tab
16 More child images are displayed
17 Choose any one image
18 Double click the image
19 Select the image and Right click the mouse button
20 Click Save picture as in Fig 8
3 Click Images tab.
Fig 8
4 Click Search image button.

ed
5 More flower images are displayed.
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6 Click any one image.
ish
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7 Opened the flower image.

8 Select the flower image and right click the mouse
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button.
9 Click Save Picture as in Fig 7.
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Fig 7
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21 Choose saving location on image

22 Click Save button

_______

272 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92

TASK 5 : Download the Software

1 Type the text google.com on internet explorer address 5 More download link displayed
bar
6 Click any one link
2 Displayed the google website
7 Click Download
3 Type the text "download winzip software" on text box
8 Choose saving location
4 Click Search button
9 Click Saved button

_______

TASK 6 : Create a new mail account

1 Type the text www.gmail.com on internet explorer Fig 10

address bar
2 Opened gmail website.
3 Click Sign up for Gmail link as in Fig 9.

Fig 9

ed
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ish
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5 Fill the all columns.

t t rig

6 Finally click I accept button as in Fig 11.

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Fig 11
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7 Created your own gmail account.

4 Opened the Application window as in Fig 10.
_______
TASK 7 : Open the Mail
1 Type the text www.gmail.com on internet explorer Fig 12
address bar.
2 Opened gmail website.
3 Type the user name and password.
4 Click Sign in button as in Fig 12.

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92 273

5 Open mail window. 7 Inbox means received mail as in Fig 14
6 Check Inbox as in Fig 13.
Fig 14

Fig 13

_______

TASK 8 : Compose email

Step 1 Fig 16
1 Click Compose mail button as in Fig 15

ed
Fig 15

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7 Click Open button.

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2 Displayed writing mail window. 8 Displayed below message as in Fig 17.

Co

3 Type the To address : example

rajesh_143@rediffmail.com Fig 17

Step 2
4 Type the Subject : example : Reg. Leave request.
5 Click Attach a file option. 9 Type the body text as in Fig 18.
6 Choose location for attached file as in Fig 16.

274 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92

Fig 18

Fig 19

ed
10 Check the spelling.
11 Finally click send button.
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12 Click Sent mail option as in Fig 19.
ish
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13 Displayed sending mail report.

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_______

TASK 9 : Check Inbox

1 Check Inbox button

2 One mail received is notified by inbox(1) as in Fig 20

Fig 20

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92 275

3 From address rajesh kannan Fig 21

4 Click the latest mail.

5 Displayed mail will be as shown in Fig 21

_______

TASK 10 : Create a New Mail account in Yahoo site

1 Type the address www.yahoo.com on internet explorer Fig 23

ed
address bar

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2 Opened yahoo web site
3 Click mail option as in Fig 22
ish
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Fig 22
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4 Opened email window

5 Click signup link as in Fig 23
6 Displayed application window

276 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92

7 Compulsory Fill all column your details as in Fig 24
Fig 24

8 Finally click these button " create my account" Fig 25

ed
9 Displayed window for account created as in Fig 25

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ish

MICT115H16
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_______
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TASK 11 : Enter the yahoo mail

o ht

1 Type the mail id and password Fig 26

2 Click Sign as in Fig 26

t t rig
No py
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92 277

3 Enter your mail account
4 Check Inbox button (received 1 mail) as in Fig 27

Fig 27

5 Check Spam mail (received 1 maill) Check the Inbox

ed
6 check online user as in Fig 28 8 Check the inbox button (1 mail received)
bl I
pu M
ish
7 Check Trash 9 Click inbox
Re NI
10 Displayed mail message
Fig 28
be @
o ht
t t rig
No py
Co

_______

278 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92

TASK 12 : Reply the mail

1 Click the Reply link as in Fig 21. 9 Deleted your current selected mail.
2 Display the compose window. 10 Displayed window for only one mail balanced as in
3 Automatically typed sender mail address. Fig 32.

4 Automatically subject typed sender subject. Fig 32

5 Only typed message as in Fig 29.

Fig 29

Check Contacts
11 Click Contacts link.
12 Displayed all contacts name as in Fig 33.

ed
bl I Fig 33
pu M
ish
Re NI

6 Finally click Send button as in Fig 30.

be @

Fig 30
o ht
t t rig

Removed your Mail

7 Click received mail check box.
No py

8 Click Delete button as in Fig 31.

Co

Fig 31

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92 279

TASK 13 : Create a New Folder
1 Choose My Folder window. 4 Type the folder name "Personal".
2 Click Add link (right side). 5 Folder "Personal" is created as in as in Fig 35.
3 Created folder name by default in untitled as in Fig 34.
Fig 35

Fig 34

MICT115H1
ed
bl I
pu M
ish
Re NI

_______
be @

TASK 14 : Rename the Folder

o ht

1 Select the Folder.

t t rig

Fig 36

2 Right click the mouse button

No py

3 Click Rename option as in Fig 36

4 Type folder name
Co

_______

280 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92

TASK 15 : Delete the Folder

1 Select the Folder. 3 Click Delete option.

2 Right click the mouse button. 4 Deleted the selected folder.
_______

TASK 16 : Move to Folder

1 Select the received mail. 4 Displayed all created folder.

2 Click the check box. 5 Select personal folder as in Fig 37.
3 Click the Move button.

Fig 37

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig

6 Moved to personal folder successfully. Fig 39

No py

7 Displayed message for There are no messages in

your inbox folder as in Fig 38.
Co

Fig 38

8 Check the personal folder.

9 Successfully moved to personal folder one mail as in
Fig 39
_______
Electronics & Hardware : Electronic Mechanic - Exercise 1.7.92 281
Electronics & Hardware Exercise 1.7.93
Electronic Mechanic - Basic Computer

Identify different types of cables and network components e.g. Hub, switch,
router, modem etc
Objectives: At the end of this exercise you shall be able to
• Idenfify cable types
• Idenfify network devices
• choose the device based on given information
• identify different types of cables and network components.

Requirements
Tools/Equipments/Instruments STP/optical cable bundle - as reqd
Modem - 1 No
• Coaxial cable bundle - as reqd
Hub - 1 No
• UTP cable bundle - as reqd Router - 1 No
Switch - 1 No

PROCEDURE

ed
TASK 1 : Identifying cables of various types
bl I
pu M
ish
1 Write the following type of cable names from the
Re NI

given images as Coaxial, UTP, STP, Optical.

be @
o ht
t t rig
No py
Co

282
TASK 2 : Identifying various devices of networking
1 Write the names of the devices as in pictures.

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

_______

Electronics & Hardware : Electronic Mechanic - Exercise 1.7.93 283

Task 3 : Select correct device for the following characteristics.
1 Choose best device based on the information given.

Based on the Information Options of the device Select correct device

1 Network information passed to all com A) MODEM

puters.

2 Receive information through internet and

pass to other devices B) HUB

3 Receive information and internet sharing

within the network C) ROUTER

ed
4 Set connection based utilities and sharing
options and connect to different networks D) SWITCH

bl I
pu M
ish
Re NI

_______
be @
o ht
t t rig
No py
Co

284 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.93

Electronics & Hardware Exercise 1.7.94
Electronic Mechanic - Basic Computer

Prepare terminations, make UTP and STP cable connectors and test
Objectives : At the end of this exercise you shall be able to
• prepare a UTP cross cable ends for making connection to the computer
• test the cable with LAN tester.

Requirements
Tools/Equipments/Instruments • Line test - 1 No
• RJ - 45 - 1 No
• Desktop computers - 2 Nos • RJ - 11 - 1 No
• Crimped tool - 1 No

PROCEDURE
TASK 1: Prepare a UTP cross cable ends for making connection to the computer

Instructor must arrange the required length of Crimp tools have two blades. One designed to
cross cable, the tool for crimping and two com- cut the cable and other to strip the jacket. While
puter for making connection as shown in stripping the cable care should be taken not to

ed
Fig 1. cut the internal wires. Remove the jacket insu-
bl I lation about an inch. When the jacket insula-
pu M
Fig 1

ish tion removed you will find eight wires twisted

into four pair for CAT 5 cable as in Fig 3 and a
Re NI

separator inside the CAT6 cable as shown in

Fig 3a.
be @
o ht

Fig 3
t t rig
No py
Co

1 Use crimping tool as shown in Fig 2 to cut through a

cable and strip the cable jacket/insulation using cable
stripper/crimping

Fig 2 Fig 3a

285
2 Cut the separator off and untwist the wires back to Fig 6
within one-eighth inch of the jacket
3 Arrange the wirees from left to right in the order they
are to be crimped. The normal crimping order for cross
cable is shown in Fig 4a & Fig 4b
The colour code wiring order is different for
both ends in cross cable

• Cross over cable

• One end
Fig 4a

Try to make each wire fits in the slot of the con-

nector and make each wire reach the end of its
slot. The cable jacket/insulation should reach
just beyond the end of the crimp point as
shown in Fig 7.

Fig 7

Fig 4b

ed
bl I
pu M
ish
Re NI
be @
o ht

4 Grasp the wires firmly between your fingers and flat-

ten them to remove the curliness
t t rig

The wires must lay flat and together aligned 7 Verify all the wires are in the correct order, and insert
No py

as closely as possible in order. when finished the connector in to the crimping tool and press to crimp
the cable should look like as shown in Fig 5 as shown in Fig 8
Co

Fig 8
Fig 5

5 Cut a few mm wihile holding them firmly, so they are Now half of the work done. The cable should
all of the same length as shown in Fig 6. look like as shown in Fig 9. The process must
be repeated for the other end of the cable. How-
6 Slide the RJ45 connector on to the wires making sure
ever the colour code wiring order changes for
the wires stay lined up
cross cable as shown in Fig 10.

286 Electronics & Hardware :: Electronic Mechanic - Exercise 1.7.94

Fig 9 Fig 10

Similarly straight through cable and roll over

cable can be prepared with the help of the in-
structor. The colour code wiring order is shown
in Fig 11
Cross over cable is used to connect between
1 Green White two hosts (PC's). Straight-through cable is
2 Green used in network when connecting a host to a
switch. A rollover cable is used in a network-
3 Orange White ing environment where a outer/switch is to be

ed
4 Blue configured from a computer. One end is wired
one way but on the other it is reversed. You
bl I
pu M
5 Blue White would typically use on end into a serial port on
6 Orange
ish a PC and the other into the console port of the
Re NI

switch/router
7 Brown White
be @

8 Brown

Fig 11
o ht
t t rig
No py
Co

_______

TASK 2: Testing the cable with the LAN tester

1 Insert one end of the cross cable (prepared in Task 1) 3 Note the order in which LED's glowing in both the panel
in to one socket and other end in another plugged in of the LAN tester should correspond to the order
socket of the LAN tester as shown in Fig 12 shown in Fig 13
Check for the batteries loaded in cable tester If the LED's doesn't glow, then there is a break in the
cable.
2 Switch 'ON' the LAN tester.

Electronics & Hardware :: Electronic Mechanic - Exercise 1.7.94 287

Fig 12 Fig 13

_______

ed
bl I
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ish
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be @
o ht
t t rig
No py
Co

288 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.94

Electronics & Hardware Exercise 1.7.95
Electronic Mechanic - Basic Computer

Connect network connectivity hardware check for its functioning

Objectives : At the end of this exercise you shall be able to
• check NIC installed
• install NIC CARD
• connect LAN Chord
• check functionatity of network.

Requirement
Tools/Equipments/
• Desk top computer or Laptop - 10
• NIC card installation

PROCEDURE
TASK 1 : Check whether NIC is installed in Desktop

1 Open whether NIC Card is installed in Desktop

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

2 Click on the Network Adapters and check the availabil-

ity of the NIC card

289
3 Right Click on the NIC Card if available and check
properties

ed
bl I
pu M
ish
Re NI
be @
o ht
t t rig
No py
Co

4 Close all the opened windows on successful check-

ing _______

TASK 2 : Installation of NIC Card if not installed

1 Insert the CD/DVD containing NIC Card driver 3 Click setup.exe in the drivers folder to install the NIC
Information (or) Download the relevant driver for NIC card.
card from Internet
4 Finish on successful installation.
2 Confirm the make of the NIC card and driver using
5 Check the card is installed properly using Device
internet checking tools
Manager, as it has no yellow or question mark near
the device.

290 Electronics & Hardware :: Electronic Mechanic - Exercise 1.7.95

6 Re-install using the 'Search for Drivers using Internet'
to find a proper driver automatically.

ed
bl I
pu M
_______

ish
Re NI

TASK 3 : Connect LAN Chord and establish network connection

be @

1 Plug one end of the NIC Card in the Desktop LAN 3 Confirm the Desktop LAN Port shows a green light,
Port (Ethernet Port). which confirms the connection is successful.
o ht

2 Plug the other end into the Switch / Hub / NIC Point 4 Preview the LAN details for TCP/IP settings to access
available. the internet from the LAN using the command in Start
t t rig

-> Run -> command ->ipconfig.

No py
Co

Note : If a DHCP server runs to connect the

LAN, it provides automatic IP address to the
connected system. No need for setting up the
IP settings. For setting up details about IP ad-
dress refer instructor.
_______
Electronics & Hardware : Electronic Mechanic - Exercise 1.7.95 291
TASK 4 : Check functionality of network

1 Click on Chrome / Firefox logo to open the browser. 3 Setup a Local Network to connect with other comput-
ers using Setup a Home Network in the control panel-
2 Type http://www.google .com in the address bar and
> Network Setup wizard.
wait for opening the Google web page.
4 Create the workgroup setup to connect with the net-
Note : If the google page appears,internet is work computers.
connected successfully. If it is not showing and
5 Set values for IP address,file sharing options to con-
displays as page cannot be displayed,internet
nect and share your system information.
is not connected.
6 Refer instructor for more utilities.

_______

ed
bl I
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ish
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be @
o ht
t t rig
No py
Co

292 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.95

Electronics and Hardware Exercise 1.7.96
Electronic Mechanic - Basic computer

Configure a wireless Wi-Fi network

Objectives: At the end of this exercise you shall able to
• Check Wifi hardware
• Connect Wifi network
• Disconnect Wifi network.

Requirements
Tools/Equipments/Instuments
• Desk top computer or Laptop - 1 No
• wifi hardware installation - 1 No

PROCEDURE
TASK 1 : Check for the availability of the wifi hardware and installation

1 Open control panel and check for the Network

adapters for the WiFi.

ed
bl I
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ish
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be @
o ht
t t rig
No py
Co

2 Check for the proper working of the WiFi device using

properties.

293
3 Install a device if not found in the system as external 4 Install driver for the device using CD or Internet
WiFi dongle. download.
5 Check in the device manager for successful
installation.

_______

TASK 2 : Connect to a WiFi network

1 Click the wireless icon in the notification area.

ed
2 Select the network you want to connect.
3 Check the Connect automatically option.
bl I
pu M
4 Click the Connect button
ish
Re NI
be @
o ht
t t rig
No py
Co

5 Enter the network security key.

6 Click the Next button.

294 Electronics & Hardware : Electronic Mechanic - Exercise 1.7.96

 Note :If the network flyout is not reporting any
wireless network, try the steps shown below
to turn off and on again Wi-Fi to see if that fixes
the problem.

ed
bl I
pu M
ish
_______
Re NI

Task 3 : Disconnect from Wi-Fi network :

1 Click the wireless icon in the notification area.
be @

2 Select the network that is currently connected.

o ht

3 Click the Disconnect button on the network connection

t t rig
No py
Co

Note :Alternatively, click the quick action Wi-

Fi button at the bottom to turn off the adapter
and disconnect from the network using flyout
menu.The same Wi-Fi button can also be found
in the Action Center's Quick Actions section
(Windows key + A). _______
Electronics & Hardware : Electronic Mechanic - Exercise 1.7.96 295
Electronics & Hardware Exercise 1.8.97
Electronic Mechanic - IC Regulators

Construct and test a +12V fixed voltage regulator

Objectives : At the end of this exercise you shall be able to
• identify the three-pin regulator IC terminal OR 7812
• construct and test a +12 volts regulator using 7812 IC.

Requirements
Tools/Equipments/Instruments • Capacitor 270 nf, disc - 1 No
• 10 μf, 25 V, electrolytic - 1 No
• DC variable power supply
• Red LED - 1 No
0-30 V, 2A - 1 No
• Resistor 820Ω, 1/4W - 1 No
• Trainees kit - 1 No
• Hook up wires (red and black colour) - 1 Mtr
• DC ammeter, 0-1A - 1 No
• Wire sleeve (R,Y,G) each - 2 cm
• Digital Multimeter - 1 No
• Rheostat 100Ω 1 A - 1 No
Materials • Resin cored solder - 10 cms
• Bread board - 1 No
• Three-pin voltage regulator
IC 7812 or equivalent - 1 No

ed
• Heat sink for 7812 - 1 No

bl I
pu M
ish
PROCEDURE
Re NI
1 From the type code marked on the given 3 pin regu-
be @

lator IC. Identify the terminals of 7812.

2 Put sleeves to the terminals using colour coding scheme
o ht

given below;
Input - Yellow/Orange sleeve.
t t rig

Common - Green/Black sleeve.

No py

Output - Red sleeve.

3 Get the work done in steps 1 and 2 checked by your
Co

instructor.
4 Fix the aluminium heat sink for 7812 on the bread
board Refer Fig 2 for the position of heat sink on the
bread board.
5 Construct the voltage regulator circuit referring to
the schematic and layout diagram shown in Fig 1 &
Fig 2.
6 Get the neatness and correctness of your wiring
checked by your instructor.
7 Apply 16 to 20 volts unregulated dc voltage to the input
of the wired 12V regulator. Record the unregulated
input voltage and no-load output voltage of the regula-
tor in O & T sheet.

The unregulated dc voltage to the regulator

should not be more than 24 volts; otherwise the
IC may get damaged.

296
8 Using loading rheostat, load the regulator in steps of 9 From the recorded readings, calculate the
200 mA upto 800mA and at each step measure and
– output voltage regulation at each step of loading.
record,
– ripple rejection at each step of loading.
- Regulated dc output voltage
10 Get your work checked by your instructor.
- Input and output ripple.
O & T Sheet
Loading is limited to 80% of its rated maximum
of 1A. This is because the heat sink used with
7812 may not be very effective in taking away
the heat.

1 Neatness and correctness of wiring: Very good Good Satisfactory Poor/Redo Continue Exercise

2 Level of unregulated input voltage to the regulator : ____________

Load - Current

No-load 200 mA 400 mA 600 mA 800 mA

ed
Output voltage

bl I
pu M
ish
Input ripple (P-P)
Re NI
Output ripple
be @

Ripple rejection
o ht

Output regulation
t t rig
No py

_______
Co

Electronics & Hardware : Electronic Mechanic - Exercise 1.8.97 297

Electronics & Hardware Exercise 1.8.98
Electronic Mechanic - IC Regulators

Identify the different types of fixed +ve and -ve regulator IC’s and the different
current ratings
Objectives : At the end of this exercise you shall be able to
• construct and test a +12 volts regulator to get a variable output regulation.

Requirements
Tools/Equipments/Instruments • Capacitor 2.2 μF, 25 μF 270 nf, disc - 1 No each
• Resistor 820Ω, 1/4W - 1 No
• DC variable power supply
• 10μf, 25 V, electrolytic - 1 No each
0-30 V, 2A - 1 No
• Red LED - 1 No
• Trainees kit
• Preset/Potentiometer 470Ω - 1 No
• DC ammeter, 0-1A - 1 No
• Resistor 1KΩ, 1/4W - 2 Nos
• Digital Multimeter - 1 No
• Hook up wires (red and black colour) - 1 Mtr
Materials • Resin cored solder - 10 cms
• Bread board - 1 No • Wire sleeve (R,Y,G) each - 2 cm
• Three-pin voltage regulator • Rheostat 100Ω 1 A - 1 No
IC 7912 or equivalent - 1 No

ed
• Heat sink for 7912 - 1 No

bl I
pu M
ish
PROCEDURE
Re NI
TASK 1 :
be @

1 Test to confirm the condition of the potentiometer or 4 Measure and record the no-load output voltages of the
pre-set. regulator at the two extreme positions of the pot/pre-
o ht

set.
2 Construct the voltage regulator circuit referring to
the schematic and layout diagram shown in Fig 1 5 Using loading rheostat, load the regulator in steps of
t t rig

200 mA upto 800mA and at each step measure and

record,
No py

- Regulated dc output voltage

- Input and output ripple.
Co

6 From the recorded readings, calculate the

- output voltage regulation at each step of loading.
- ripple rejection at each step of loading.
7 Get your work checked by the instructor.

Solder the potentiometer/pre-set across tags 10-11-12.

3 Apply unregulated dc voltage of 20V to the regulator.
Record applied input voltage.

298
 Observation & Tabulation Sheet

1 Level of the unregulated input voltage to the variable output regulator : ____________

Load - Current

No-load 200 mA 400 mA 600 mA 800 mA

Output voltage

Input ripple (P-P)

Output ripple

Ripple rejection

Output regulation

2 No-load output voltage levels: (i) Minimum adjustable: (ii) Maximum adjustable :

ed
_______

bl I
pu M
ish
TASK 2 :
Re NI
1 Check the Components by using multimeter 3 Apply unregulated dc voltage of -20V to the circuit
2 Construct variable voltage regulator 4 Measure and record the regulated dc output voltage of
be @

the regulator at the two extreme positions of the circuit.

5 Get your work checked by the instructor.
o ht

Specification
t t rig

• 1.5 A Output Current

No py

• High ripple rejection

• Thermal short circuit and safe area projection.
Co

Observation & Tabulation Sheet

1 Level of the unregulated input voltage to the variable output regulator : ____________

Load - Current

No-load 200 mA 400 mA 600 mA 800 mA

Output voltage

Input ripple (P-P)

Output ripple

Ripple rejection

Electronics & Hardware : Electronic Mechanic - Exercise 1.8.98 299

IC 79xx requires heat sink for its safe operation. Heat sink What is a Voltage Regulator IC?
boosts heats dissipation therefore the life of the device
Voltage regulatorIC can be defined as an integrated cir-
can be extended.
cuit that is capable of supplying a constant controlled
IC Number Output Voltage output voltage which is not at all affected by the varia-
tions in put voltage provided that the varioations are within
the prescribed limits under specified atmospheric
7905 -05 Volts
condtions. Voltage fluctuations may be damage or re-
duce the life of circuit components. Usage of voltage regu-
7912 -12 Volts lator ICs helps in avoiding such events by maintaining
voltage at the required levels.
7915 -15 Volts
IC 79xx
7918 -18 Volts IC 79xx is a three pin negative controller IC. It is a small
integrated circuit to supply a constant negative input
voltage. The number 79 indictesthat it is a negative
voltage egulayor and xx indicates the output voltage of the
IC. “ can be replaced by the controlled output voltage
provided by the regulator, for example, if it is 7905, then
the out put voltage of the IC is 5V. Similarly if it is 7912
thne output voltage od the IC is -12v volt and so on. The
name of the IC may vary bqsed onthe manufactureer as
LM79xx, L79xx, MC 79xx etc.
Conection Diagram

ed
IC 79xx is used in circuits a shown in the circuit. In order

bl I
pu M to improve stability two capacitors- C1 and C2 are used.

ish
The pin 1 acts as the Ground terminal (OV) The pin 2 The capacitor C1 is used only if the regulator is separated
acts as the input terminal (5v to 24V). The pin 3 acts as
Re NI
from the filter capacitor by more than 3”. It must be 22μ
the output terminal (constant regulated 5V) F solid tantalum capacitor or 25 μF aluminum electrolytic
Pin out Configuration of IC 79xx. capacitor. The capacitor C2 is requred for stability. Usually
be @

The pin out configuration of IC 79xx is shown in the 1μ F solid tantalum capacitor is ued. One can also use 25
diagram below. F aluminum electrolytic capacitor. Value given may be
o ht

• The pin 1 acts as the Gtound terminal (OV) incresed without limit.

• The pin 2 acts as the input terminal (5V to 24V) 79xx Connectiondiagram.
t t rig

• The pin 3 acts as the output terminal (constant

No py

regulated 5 V)
IC 79xx (7905, 7912, 7915, 7918) - Negative Voltage
Co

Regulator
79xx votlage regulators are very commonly used in
electronic circuits. The main purpose of this IC is to supply
required regulated negative voltage to the circuits. IC
79xx can supplya constant negative voltage output, in
spite of any voltage fluctions in its input coltage.It canbe
mainly found in the circuits in which integratedcircuits that
require +Vcc and Vcc are used.

_______
300 Electronics & Hardware : Electronic Mechanic - Exercise 1.8.98
Electronics & Hardware Exercise 1.8.99
Electronic Mechanic - IC Regulators

Identify different heat sinks for IC based regulators

Objectives : At the end of this exercise you shall be able to
• identify the different+ve and _ve regulator ICs
• Identify the types of package
• Identify the different heat sinks for regulators ICS.

Requirements
Tools/Equipments/Instruments Materials
• Trainees kit - 1 No • Assorted 3 terminal fixed
regulators ICs - 10 Nos
• Assorted heat sinks - 10 No
• Thermal taps - 5 Nos
• Nut and Bolts - as reqd

PROCEDURE
TASK 1 : Identify different types of fixed +ve and -ve regulator ICs

ed
bl I
1 Pick a regulator IC
pu M 4 Record the current rating by its of the diode packing

ish
style.
2 Identify it depening on its packaging style or the
Re NI
number printed on it. 5 Repeat the above steps for 79xx series regulators and
record your observations in Table 1.
3 Refer data book and identify its input, common and
be @

output terminals 6 If the number printed on it is 78xx it is a +ve regulator

79xx will be -ve regulator.
o ht
t t rig

Table 1
1. IC specificaations from marked code
No py

Type code Manufacturer Type of regulator Output Reted Max Package type
Co

Positive Negative voltage load current

_______

301
TASK 2 : Identify the heat sink and mounting on IC regulators

1 Select and pick a heat sink from assorted heat sinks 7 Check the work sheet by instructor
provided.
8 Repeat above steps for other one.
2 Measure the size of heat sink and count the number
Mounting Heatsink
sides & slots available on it.
1 Clean the surface of heatsink & component.
3 Observe and record the material used to make heat
sink. 2 Place the thermal tape on heatsink.
4 Note points of mount holes available for component & 3 Fix the component in proper direction on heatsink
for heat sink on body mounting. body.
5 Get the help of instructor to find type of mounting 4 Screwing nut andbolt at identified points for tighting.
(surface mounting and through hole mounting.
5 Check the work by Instructor.
6 Identify the heats some suitable for flat packages or for
to packages etc.,

Table 2

S.No. Name of Heatsink Shape Name of Heatsink Materials No.of faces Suitable to package

ed
bl I
pu M
ish
Re NI
be @

_______
o ht
t t rig
No py
Co

302 Electronics & Hardware : Electronic Mechanic - Exercise 1.8.99

Electronics & Hardware Exercise 1.8.100
Electronic Mechanic - IC Regulators

Observe the output voltage of different IC723 metal / plastic type and IC 78S40
regulators by varying the input voltage with fixed load
Objectives : At the end of this exercise you shall be able to
• observe the output voltage of IC 723 and IC 78S40 regulators.

Requirements
Tools/Equipments/Instruments Materials
• Trainees kit - 1 No • Bread board - 1 No
• Soldering Iron 25W - 1 No • IC 723 - 1 No
• Digital multimeter - 1 No • Capacitor 100PF Resistors - 1 No
• 1 KΩ Carbon 1/2 W - 1 No
• 2.7 KΩ Carbon 1/2 W - 1 No
• 6.8 K Carbon 1/2W - 1 No
• 4.7 K carbon 1/2W - 1 No
• 10 Ω Potentiometer 1A carbon - 1 No
• Ammeter (6-14) - 1 No

ed
bl I
PROCEDURE
pu M
ish
1 From the type code marked on the given 14 pin Table 1
Re NI
posture regulator IC.
2 Identify ithe pins of IC 723 and put sleeves to the S No. Input voltage Output voltage in volts
be @

terminals using colour coding scheme given below (Vi) in Volts (Vo) in Volts

Input Yellow / Orange Sleeve

o ht

Output Red sleeve

t t rig

Earth - Green / Black sleeve.

3 Get the work done in steps 1 & 2 checked by your
No py

instructor.
4 Construct the voltage regulator circuit referring to the
Co

schematic circuit diagram shown in figure.

5 Get the neatness and correctness of your wiring
checked by your instructor.
6 Apply reguated dc voltage to the input of the wired
regulator. Record the output voltage of the regulator
in O&T sheet.
7 From the recorded readings.Calculate the output
voltage regulation at each step and plot the graph.
8 Get your work checked by the instructor.

303
 ed
bl I
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ish
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be @
o ht
t t rig
No py
Co

_______

304 Electronics & Hardware : Electronic Mechanic - Exercise 1.8.100

Electronics & Hardware Exercise 1.8.101
Electronic Mechanic - IC Regulators

Construct and test a 1.2V-30V variable output regulated power supply using IC
LM317T
Objectives : At the end of this exercise you shall be able to
• construct and test a 1.2 V to 30 V variable output regulated power supply.

Requirements
Tools/Equipments/Instruments 25 μF, 50V, electrolytic - 1 No
10 μF, 50V, electrolytic - 1 No
• Trainees kit - 1 No
100 nF, ceramic disc - 1 No
• Solding Iron 25 W - 1 No
• LED, Red - 1 No
• Digital Multimeter - 1 No
• Resistors
Materials 4K7, potentiometer, carbon, rotary - 1 No
2K2, carbon, 1/2W - 1 No
• Bread board - 1 No
220W, carbon, 1/4W - 1 No
• Step down transformer, 240V; 24V
• 3-terminal voltage regulator, LM317T,
or 240: 12-0-12, 24VA - 1 No
TO-220 - 1 No
• Diodes, 1N4002 or BY127 or Equv - 6 Nos
• 1A, slow blow fuse with fuse holder - 1 No.
• Capacitors 2200 μF,
• Hook up wires - as reqd

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50V, electrolytic - 1 No
• Resin cored solder - 20 cms

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• Heat sink for TO-220 package - 1 No
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• Rheostat 100Ω 1 A - 1 No
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PROCEDURE
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1 Test all the components to confirm their good working All components except the transformer to be
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condition. Record the specifications of IC LM317T in mounted on bread board. Use suitable heatsink
O&T sheet. with IC 317 T.
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2 Check the given bread board.

5 Get the correctness and neatness of wiring checked
3 Construct a variable regulated output power supply on
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by your instructor.
the given bread board referring to the circuit schematic
shownin Fig 1. 6 Connect the secondary of (230:24V) transformer to
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the wired circuit. Switch ON mains supply.

305
 10 Using a dc current meter (0-1A range) short the load
Switch OFF main supply immediately if burning,
terminals momentarily and record the short circuit fold
smoking overheating, sparks are observed in
back protection current level.
any of the components, and report to your
instructor. Check the IC and ensure that it is not 11 Get the readings checked by your instructor.
heated-up
Lab Assignment : Mount the regulator IC on a
7 Measure and record the unregulated dc input and the good aluminium heat-sink (available in mar-
minimum, maximum variable voltage of the regulator ket). If a good heat-sink is used with the IC, you
under no-load condition. can draw upto 1Amps easily. Mount the trans-
former and the wired PCB in a metallic box of
8 Set the output to +15 volts and load the output using a suitable size. Mount the POT on the front panel
loading rheostat in steps of 200 mA up to 600 mA. In of the box made. Mount output terminal sock-
each step measure and record the output voltage and ets (Red and black) on the front panel of the box
the ripple voltages. from which DC voltage can be taken. This will
serve you as a 1.2V to 30V, 1A rating variable
Load current is restricted to 600mA as heat-
power supply for servicing circuits in forth-
sink is provided to the IC may not be the ideal
coming exercises as well for your hobby
one.
gadgets and general servicing.
9 Calculate and record the output regulation and ripple
rejection of the regulator.

Observation & Tabulation Sheet

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1 Specification of the given 3-terminal regulator IC.

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Type Package Output voltage Max. output
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number type current
Min. Max.
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2 Neatness and correctness of wiring: Very good Good Satisfactory Poor/Redo Continue Exercise
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3
Unregulated dc input to regulator : ____________________
Minimum adjustable output voltage (No-load) : ____________________
Maximum adjustable output voltage (No-load) : ____________________

4
Set output voltage : 15 volts

Load current 200mA 300mA 400mA 500mA 600mA

Output voltage

Output ripple (p-p)

Input ripple

Output regulation

5 Shorted output current I :

SC

306 Electronics & Hardware : Electronic Mechanic - Exercise 1.8.101