Electricity Y3

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Unit of Competency : INSTALL ELECTRICAL LIGHTING SYSTEMS ON AUXILIARY OUTLET AND LIGHTING FIXTURES

Module No.

1

Module Title: Installing of Electrical Lighting System on Auxiliary Outlets and Lighting Fixtures

Republic of the Philippines

Department of the Education PUBLIC TECHNICAL-VOCATIONAL

HIGH SCHOOLS

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ACKNOWLEDGMENT

Copyright Department of Education 2008

First Published JUNE 2008

This draft was prepared during the Competency-Based Learning Materials Development Workshop conducted at the Marikina Hotel, Marikina City on February 18-22, 2008 and finalized on May 23-25, 2008 at the Development Academy of the Philippines (DAP), Tagaytay City.

This learning instrument was developed by the following personnel: Technology Teachers:

 MR. MARINO C. CUETO

Community Vocational High School MinSCAT Calapan City Campus, Masipit, Calapan City

Contextual Teachers:

 MS. GINA C. DELOS SANTOS AFG Bernardino MTS

Lias, Marilao, Bulacan Facilitator:

 MRS. CORAZON C. ECHANO Tech-Voc Task Force

Encoder

 MR. LEMUEL C. VALLES Fund: Department of Education.

REFERENCES AND FURTHER READING:

Balana, Ulysses B., TLE III Electricity, Eferza Academic Publication,

2004, pp.

Handley, William, Industrial Safety Handbook, McGraw-Hill Book Co.;

1977, pp.

Hubert, Charles I. Preventive Maintenance of Electrical Equipment –

2nd_{Ed., New York: McGraw Hill Book Co.; 1974, pp.}

Institute of Integrated Electrical Engineers, Inc. Phillippine Electrical

Code, Part I, 2002, # 41, Monte de Piedad St., Cubao, Quezon City, Philippines: Bookman Inc., June 2002.

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HOW TO USE THIS MODULE

Welcome to the Module “Installation of Electrical Lighting System on Auxiliary Outlets and Lighting Fixtures”. This module contains training materials and activities for you to complete.

The unit of competency “Install Electrical Lighting System on Auxiliary Outlets and Lighting Fixtures” contains the knowledge, skills and attitudes required for a Building Wiring Installation course. It is one of the specialized modules at National Certificate (NC) Level II.

You are required to go through a series of learning activities in order to complete each of the learning outcomes of the module. In each learning outcome there are Information Sheets, Job Sheets, Operation Sheets and Activity Sheets. Do these activities on your own and answer the Self-Check at the end of each learning activity.

If you have questions, do not hesitate to ask your teacher for assistance.

Recognition of Prior Learning (RPL)

You may already have some or most of the knowledge and skills covered in this module. If you can demonstrate competence to your teacher in a particular skill, talk to him/her so you do not have to undergo the same training again. If you have a qualification or Certificate of Competency from previous trainings show it to him/her. If the skills you acquired are consistent with the relevant to this module, they become part of the evidence. You can present these for RPL. If you are not sure about your competence/skills, discuss this with your teacher.

After completing this module ask your teacher to assess your competence. Result of your assessment will be recorded in your competency profile. All the learning activities are designed for you to complete at your own pace.

Inside this module you will find the activities for you to complete and relevant information sheets for each learning outcome. Each learning outcome may have more than one learning activity.

This module is prepared to help you achieve the required competency, in receiving and relaying information. This will be the source of information that will enable you to acquire the knowledge, skills and attitude in Building Wiring Installation National Certificate (NC) Level II independently at your own pace or with minimum supervision or help from your teacher.

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Course BUILDING WIRING INSTALLATION

Unit of Competency INSTALL ELECTRICAL LIGHTING SYSTEM ON AUXILIARY OUTLETS AND LIGHTING FIXTURES Module Title Installation of Electrical Lighting System on

Auxiliary Outlets and Lighting Fixtures

INTRODUCTION:

This module contains the “know” and “do” units in Installation of Electrical Lighting System on Auxiliary Outlets and Lighting Fixtures.

It covers the knowledge, skills and attitudes required in installing the lighting fixtures. Specifically, this module covers installation of knob and tube, PVC raceway/molding, rigid non-metallic conduit, flexible non-metallic conduit, fluorescent lighting fixtures, and incandescent lamp

This module consist of seven (7) Learning Outcomes (LO’s) that contain learning activities for both knowledge and skills supported with information sheets, job/operation sheets and self-check. Before attempting to perform the manual exercises, see to it that you have already read and understood the information/operation sheet and answered correctly the self-check provided in every Learning Activities.

SUMMARY OF LEARNING OUTCOMES:

Upon completion of this module, the students shall be able to:

LO1. Layout and install electrical wiring using knob and tube method LO2. Layout and install PVC raceway/molding

LO3. Layout and install rigid non-metallic conduit LO4. Layout and install flexible non-metallic conduit LO5. Assemble fluorescent lighting fixtures

LO6. Layout and install fluorescent lighting fixtures LO7. Layout and install incandescent lamps

ASSESSMENT CRITERIA:

Refer to the assessment criteria of learning outcomes # 1-7 of this module.

PREREQUISITES:

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TECHNICAL TERMS

Ballast is an induction coil which produces high voltage to start the lamp into operation.

Fluorescent tube is a circular bulb containing mercury vapor and inert gas with phosphor coating inside.

Frame is the metal housing of the whole fixture.

Incandescent bulb is a light source with a metal filament that glows with white heat.

Insulation is a nonconductive device covering that protects wires and other electricity carriers.

Junction box is an enclosure used for splitting circuits into different branches.

Knockouts are tabs that can be removed to make opening in a box for cable and conduit connector.

Knick is small cut on wires.

Limelight comes from the incandescent light produced by a rod of lime bathed in a flame of oxygen and hydrogen.

Non-metallic conduits are electrical materials which are manufactured to be resistant to moisture and chemical atmosphere.

Photographic lamps as the name implies, are used in photography and projection service.

Receptacle is an outlet that supplies power for lamp and other plug-in devices

Screw cap is the threaded base of the bulb that secures it to a lamp. Solid knobs are used to support or anchor wires as big as No. 8 or even bigger.

Split knobs are used to support wires smaller than No. 8. Support wires are wires that physically hold up the filament.

Vinyl Chloride is a toxic carcinogen which has been proven to cause angiosarcoma, a deadly primary liver cancer.

AWG – American Wire Gauge PEC – Philippine Electrical Code PPE – Personal Protective Equipment PVC – polyvinyl chloride

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Course : BUILDING WIRING INSTALLATION

Unit of Competency : INSTALL ELECTRICAL LIGHTING SYSTEM ON AUXILIARY OUTLETS AND LIGHTING FIXTURES Module Title : Installing of Electrical Lighting System on

Learning Outcome 1: Layout and install electrical wiring using knob and tube method

Assessment Criteria:

1. Electrical wiring is installed in line with the job requirements. 2. Electrical wiring is installed in line with the PEC/NEC.

3. Safety procedure in installing electrical wiring is strictly followed in line with the Occupational Safety and Health Standards.

References:

1. Johnston, Larry et.al., Better Homes and Gardens Wiring 1st_{Edition, Meredith Books; 2007,pp.}

2. Mulin, R.C., Smith R.L. Electrical Wiring-Commercial, Six Ed., New York: Delmar’s Publishing Inc.; 1984, pp. 3. Agpoa, Feleciano. Interior and Exterior Wiring

Troubleshooting ; National Bookstore: 1991 4. www.diydata.com/tool/drills/drills.php 5. www.powertoolinstitute.com

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LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome # 1: Layout and install electrical wiring using knob and tube methods

Learning Activities Special Instructions

1. Read the Information sheet 1.1 about the principle of knob and tube.

 You can ask assistance from your teacher to show you and explain further the topic you cannot understand well. 2. Perform the job sheet 1.1 on

installing one bulb controlled by one single pole switch in one location.

 Perform the performance test

3. Perform the job sheet 1.2 on installing two bulbs controlled individually by two single pole switch in two location.

 Perform the performance test

4. Perform the job sheet 1.3 on installing one bulb controlled by two three-way switch in two locations.

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INFORMATION SHEET 1.1

PRINCIPLES OF KNOB AND TUBE

The open or exposed wiring method is sometimes referred to as the Open Wiring on Insulators. (PEC section 212) It uses cleats, knobs (split or solid), porcelain tubes and mica tubing for the support and protection of insulated conductors run in or on buildings. It may be used in working either outside or inside building in dry or wet locations. It shall not be used in the following locations:

1. Commercial Garages 2. Theaters

3. Motion Picture Studios 4. Hoist ways

5. Hazardous Locations

In the open or exposed wiring method, the wires are visible and are supported by the knobs. These knobs may be a split or solid type. This is shown in figure 1.

Figure 1. The Split and Solid knobs

Split knobs are used to support wires smaller than No. 8. Solid knobs are used to support or anchor wires as big as No. 8 or even bigger. Screws or nails may be used to fasten the knobs. When a nail is used a leather washer should be placed between the nail head and the insulator to form cushion and protect the insulator from breaking. See figure 2.

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Figure 2. The Solid Knob with Leather washer for Protection

Figure 3. Shows the correct and wrong ways of tying wires to the groove of a solid knob.

In installing an electrical wiring system with the exposed knob and tube wiring method, the distance between conductors should be maintained at a minimum distance of 6 cm. (2 ½ inches) apart. The knobs must have a 30 cm (1 foot) distance apart. Figure 4 illustrates this provision of PEC.

Figure 4. Spacing of Split Knobs and Conductors

Whenever wires pass through studs, rafters, floor joists or any wooden part of a building, the wires are inserted in porcelain tubes or flexible mica tubing. Porcelain tubes and mica tubing are also provided whenever wires cross each other. It gives the wire extra protection from injury.

30 cm. 1 Ft.

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Figure 5. Application of Porcelain Tubes and Mica Tubing

Some advantages of the Knob and Tube wiring:

1. It is used in temporary installation, such as construction jobs. 2. It has economical when properly installed.

3. It has a lower operating temperature because of ventilation brought by distances of the installation.

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Safety reminders when installing knob and tube wiring

1. Apply enough pressure on the gimlet when driving it to the wood board. Never hammer it.

2. Have the auger brace oiled regularly especially the ratchet type.

3. Have your electrician’s knife sharpened enough in order not to nick the wire.

4. Use the appropriate screw driver for the screw.

5. Be sure that the conductors in contact with the wiring surface are enclosed in mica tubing.

6. Be sure that your teacher has checked your work before testing.

7. Be sure that the safety switch is off before making any connection. Apply tape on all joints/splices.

8. Do not drive the split-knobs completely before the conductors or wires are run or inserted along the grooves of the knobs.

9. Be sure to test the insulation for short and ground circuit before putting on the power.

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JOB SHEET 1.1

Installing one bulb controlled by one single pole single throw (SPST) switch in one location.

Name ________________________________________ Year/Section: _____ Date _________________________________________ Overall Rating ____ I – Materials Required

Qty Unit Description

1 pc single pole, tumbler switch, surface type 1 pc porcelain/plastic receptacle, surface type 1 pc incandescent bulb, 220v, 25w

7 mts solid wire # 14 t.w.

11 pcs porcelain/plastic split knobs with screws 1 ft mica tubing or loom

1 roll electric tape

1 pc safety switch/cut out 2 pcs fuse, 10-a, cartridge type II- Tools Needed

Screwdrivers electrician’s knife Pliers pull push tape rule hammer

III – Procedure

Perform this procedure:

1. Prepare all tools and materials needed.

2. Wear appropriate PPE.

3.Install porcelain/plastic receptacle and porcelain cut-out/safety switch to the desired location.

4. Fasten knobs to their proper places. Do not tighten screws. Provide distance for the insertion of wires.

5.Provide mica tubing in every termination of connection of the wires. 6.Make connection from receptacle to safety switch and another connection from switch to safety switch. Tighten screw of knobs.

7.Fasten the switch. Provide porcelain base under it.

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Instruction: When you are ready to perform this task, ask your teacher to observe the process and to rate your performance using the assessment criteria. Follow the pictorial diagram.

Assessment Criteria

Dimensions VS ₅ S ₃ NI ₁

1. Quality: Workmanship, Appearance, Verticality, Horizontality

2. Accuracy: Dimension;(optional) Accurate function of the elements

3. Method: Observance of the safety measures

4. Speed: Submission on time +1, before the expected time +2, after the expected time – 2

Rating Scale:

VS – Very Satisfactory = 15 – 11 S – Satisfactory = 10 – 5 NI – Needs Improvement = 6 and below

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I do hereby certify that my student has satisfactorily passed this performance test by demonstrating their ability in installing one outlet controlled from one location.

Conforme: Attested:

_________________ __________ _______________ _______ Student Date Teacher Date

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JOB SHEET 1.2

Installing two bulbs controlled individually by two single pole switch in two locations

Name ________________________________________ Year/Section: ____ Date _________________________________________ Overall Rating ____ I – Materials Required

2 pcs single pole, tumbler switch, surface type 2 pcs porcelain/plastic receptacle, surface type 2 pcs incandescent bulb, 220v, 25w

1 pc safety switch/cut out 2 pcs fuse, 10-a, cartridge type II – Tools Needed Set of screwdrivers Set of pliers hammer gimlet electrician’s knife III- Procedure

1. Prepare all tools and materials needed.

2. Wear appropriate PPE.

3. Install porcelain/plastic receptacle and porcelain cut out/safety switch to desired location.

4. Fasten split knobs to proper location and distances. Do not tighten screws. Provide clearance for insertion of wires.

5. Provide mica tubing in every connection of the wires. Follow the figure/drawing as shown.

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7. Fasten switches with base under it.

8. Mount the bulbs and fuses on their respective locations. 9. Connect the power and test the installation

Instruction: When you are ready to perform this task, ask your teacher to observe the process and rate your performance using the assessment criteria. Follow the pictorial diagram.

1. Quality: Workmanship, Appearance, Verticality, Horizontality

2. Accuracy: Dimension;(optional) Accurate function of the elements

3. Method: Observance of safety measures

4. Speed: Submission on time +1, before the expected time +2, after the expected time – 2

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Rating Scale:

VS – Very Satisfactory = 15 – 11 S – Satisfactory = 10 – 5 NI – Needs Improvement = 6 and below I do hereby certify that my student has satisfactorily passed the

performance test by demonstrating his ability in installing two outlets,

controlled individually by two single pole single throw switch in two location.

Conforme: Attested:

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JOB SHEET 1.3

Installing one bulb, controlled from two location by two-3-way switch Name ________________________________________ Year/Section: _____ Date _________________________________________ Overall Rating ____ I – Materials Required

2 pcs three-way switch, surface type

1 pc porcelain/plastic receptacle, surface type 1 pc incandescent bulb, 220v, 25w

1 pc safety switch/cut out 2 pcs fuse, 10-a, cartridge type II – Tools Needed Set of screwdrivers Set of pliers hammer gimlet electrician’s knife III- Procedure

1.Prepare all tools and materials needed.

2.Wear appropriate PPE.

3.Install porcelain/plastic receptacle and porcelain cut out/safety switch to desired location.

4Fasten split knobs to proper location and distances. Do not tighten screws. Provide clearance for insertion of wires.

5.Provide mica tubing in every connection of the wires. Follow the figure/drawing as shown.

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7.Fasten switches with base under it.

8.Mount the bulbs and fuses on their respective locations. 9.Connect the power and test the installation

Instruction: When you are ready to perform this task, ask your teacher to observe the process and to rate your performance using the assessment criteria. Follow the pictorial diagram.

1. Quality: Workmanship, Appearance, Verticality, Horizontality

2. Accuracy: Dimension;(optional) Accurate function of elements

3. Method: Observance of safety measures

4. Speed: Submission on time +1, before the expected time +2, after the expected time – 2

Rating Scale:

VS – Very Satisfactory = 15 – 11 S – Satisfactory = 10 – 5

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NI – Needs Improvement = 6 and below I do hereby certify that the student has satisfactorily passed the

performance test by demonstrating his ability in installing two outlets, controlled individually by two single pole single throw switch in two location.

Conforme: Attested:

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Learning Outcome 2: Layout and install PVC raceway/molding Assessment Criteria:

1. Materials, tools and equipment for installing PVC raceway are prepared in line with the job requirements.

2. PVC raceway is installed in line with the job requirements.

3. Workplace is cleaned and made safe upon completion of the job. 4. PEC provisions concerning PVC raceway installations are strictly

followed.

5. Final report is prepared upon the completion of job. References:

1. Johnston, Larry et.al., Better Homes and Gardens Wiring 1st Edition, Meredith Books; 2007,pp.

2. Mulin, R.C., Smith R.L. Electrical Wiring-Commercial, Six Ed., New York: Delmar’s Publishing Inc.; 1984, pp.

3. Agpoa, Feleciano. Interior and Exterior Wiring Troubleshooting ; National Bookstore: 1991

4. www.diydata.com/tool/drills/drills.php 5. www.powertoolinstitute.com

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LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome 2: Layout and install PVC raceway/molding

1. Read Information sheet 2.1

about PVC raceway/molding.  You can ask assistance from your teacher to explain his topics you cannot understand well.

2. Perform job sheet 2.1 on installing PVC

raceway/molding.

 Observe the demonstration of your teacher and check the technique while observing.

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INFORMATION SHEET 2.1

Surface Raceway is a one piece, non-metallic, adhesive backed latching raceway designed to aesthetically organize and route low voltage communications cables. It features a low profile design which blends into any environment whether it is new construction or a renovation. It is easy to cut and trim and is also printable with a latex based paint. It provides a complete line of fittings to manage connectivity requirements.

The fittings are available for each size raceway and color option. Single or Dual gang, junction boxes are versatile enough for any electrical application. Boxes are equipped with concentric knockouts for all 3 sizes of raceway. Knockouts are provided on all four sides. Junction boxes come with adhesive strips and #6 screws to secure the box to the base.

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The National Electrical Code permits surface raceways in dry locations for exposed or surface work. The raceway can be extended through dry ways, dry partitions, and dry floors if one continuos length of raceway is used throughout the concealed section.

The raceway cannot be used for concealed work on locations subject to severe to corrosive vapors, or in hoist ways and hazardous location.

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JOB SHEET 2.1

Layout and install PVC raceway/molding

Installing one bulb controlled by one single pole switch in one location. I. Materials Required

Quantity Unit Descriptions

1 pc single pole switch (flush type)

1 pc safety switch

1 pc incandescent bulb (25 w)

1 pc receptacle

1 pc junction box

2 pcs fuse 15 A (cartridge type)

1 pc metal/plastic box

1 roll electrical tape

1 ft mica tubing or loom

2 pcs plastic molding

20 pcs wood screw (1/2)

II. Tools Needed

side cutting plier combination plier long nose plier philips screw driver standard screw driver hammer

hacksaw III. Procedure

1. Prepare all the materials needed 2. Wear appropriate PPE.

3. Install lamp receptacle, junction box, metal box, safety switch to the desired location.

4. Fasten the PVC molding to its proper location following the desired measurements.

5. Connect the wires to where it is intended. Refer to the schematic diagrams.

6. Mount the bulb and fuses on their respective locations. 7. Connect the power and test the installation.

Schematic diagram of one bulb

controlled by a single pole switch using PVC molding.

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Assessment Criteria CRITERIA Points Accuracy of connection 15 Workmanship - Cutting of PVC molding 15 - Measurements 5 Use of tool 5 Speed 5 Housekeeping 5 50 pts

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Course :

BUILDING WIRING INSTALLATION

Learning Outcome 3: Layout and install rigid non-metallic conduit Assessment Criteria:

1. PEC provisions in installing rigid non-metallic conduit are strictly followed.

2. Personal safety in installing rigid non-metallic conduit is followed. 3. Tools/materials and equipments needed for installation are prepared

in line with job requirements.

4. Rigid non-metallic conduit is installed in line with the job requirements.

5. Final report is prepared upon the completion of the job. References:

1. Johnston, Larry et.al., Better Homes and Gardens Wiring 1st Edition, Meredith Books; 2007,pp.

2. Mulin, R.C., Smith R.L. Electrical Wiring-Commercial, Six Ed., New York: Delmar’s Publishing Inc.; 1984, pp.

3. Agpoa, Feleciano. Interior and Exterior Wiring Troubleshooting ; National Bookstore: 1991

4. www.diydata.com/tool/drills/drills.php 5. www.powertoolinstitute.com

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LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome 3: Layout and install rigid non-metallic conduit Learning Activities Special Instructions

1. Read Information sheet 3 2. .1 about rigid non-metallic

conduit

 You can ask assistance from your teacher to show and explain further the topics that

you cannot understand well. 3. Perform operation sheet 3.1 on

bending 90°PVC elbow.  Observe the demonstration of your teacher and check the technique while observing.  Teacher supervises the student

performance.

4. Perform operation sheet 3.2

PVC offset bending.  Observe the demonstration of your teacher and check the technique while observing.  Teacher supervises the student

performance.

5. Perform job sheet 3.1 on how to install by two bulbs controlled by two three-way switch and one SPST with two

convenience outlets.

 You can ask assistance from your teacher to show you and

explain furtherly information that you cannot understand

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INFORMATION SHEET 3.1 Rigid Non-Metallic Conduit (PVC)

Non-metallic conduits are electrical materials which are manufactured to be resistant to moisture and chemical atmosphere. They are also manufactured to be flame retardant or not easily burned. They are resistant to impact and crushing. They do not easily get out shape by the heat. These conduits are classified according to the materials they are made of. The most common ones are asbestos cement conduit, polyvinyl chloride, conduit and high density polyethylene conduit.

The Philippine Electrical Code provides that rigid non-metallic conduit may be used under the following conditions:

1. Concealed in floors, walls and ceilings 2. Direct earth burial or underground

 300 mm in trench below 50mm thick concrete or equivalent

 600 mm under streets, highways, roads, alleys, driveway and parking lots

 460 mm under driveways and parking lots of single and two family dwelling units

 460 mm under airport runways, including adjacent areas where trespassing is prohibited

3. In locations subject to severe corrosive influences

4. In locations where subject chemicals for which the materials are specifically approved

5. Cinder fill

6. In wet locations, provided water is prevented from entering the conduit

7. In dry and damp locations

The Philippine Electrical Code prohibits the use of rigid non-metallic conduit under the following conditions:

1. Hazardous (Classified) locations 2. Support of fixtures

3. Physically damaged location

4. Ambient temperature. Where subject to ambient temperatures in excess of 50o_{C unless listed otherwise}

5. Insulation temperature limitations. For conductors whose insulation temperature limitations would exceed those for which the conduit is listed.

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INSTALLATION OF NON-METALLIC CONDUIT PEC REQUIREMENTS 1. TRIMMING. Rough edges or burrs at the cut ends of non-metallic

conduit shall be trimmed inside and outside

2. JOINTS. Joints between lengths of conduit and between conduit couplings, fittings and, boxes shall be made with approved coupling and adapter. For water proofing, PVC cement should be spread around the surfaces to be .joined together

3. SECURING and SUPPORTS. Rigid non-metallic conduit shall be rigidly supported as indicated below

Table 3.47.1.8 Support of Rigid Nonmetallic Conduit (Based on Philippine Electrical Code, 2000, Part I)

Conduit Size

[mm (mm)]* Between Supports (mm) Maximum Spacing 15 (20) – 25 (32) 32 (40) – 50 (63) 65 (75) – 80 (90) 90 (100) – 125 (135) 150 (160) 900 1500 1800 2100 2400

4. EXPANSION FITTINGS. Expansion fitting for rigid nonmetallic conduit shall be provided to compensate for thermal expansion and contraction.

5. MINIMUM SIZE. Rigid nonmetallic conduit smaller than 15 mm (20 mm) electrical trade size shall not be used.

6. MAXIMUM. Rigid nonmetallic conduit larger than 150 mm (160 mm) electrical trade size shall not be used.

7. BUSHING. Where conduit enters a box, fitting or other enclosure, a bushing or adapter shall be provided to protect wires from abrasion unless the box, fitting or enclosure design provides equivalent protection.

8. BENDS-HOW MADE. Bends of rigid nonmetallic conduit shall be so made that the conduit will not be damaged and that the internal diameter of the conduit will not be effectively reduced.

Table 3.46.2.6 Radius of Conduit Bends (Based on Philippine Electrical Code, 2000, Part I) Size of Conduit

(mm) Conductors Without Lead Sheath 15 20 25 32 40 50 65 100 125 150 200 250 300 375

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80 90 100 125 150 450 525 600 750 900 TYPES OF PVC CODUIT FITTINGS

PVC Coupling PVC elbow

Adapter PVC Conduit Pipe

PVC 2G box LL Access Fitting

1 Inch Type T Condulet 1/2 Inch Type T PVC _Condulet

3/4" Type LL PVC Access

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Identifying Different Types of Bend

The PVC or polyvinyl chloride rigid conduit is one of the most commonly used conduits in electrical wiring installation today. Its preparation for installation is much easier than the metallic rigid conduit. In preparing a non-metallic rigid conduit for installation, an electrician needs to do cutting, heating and bending. Like in metallic rigid conduit offset bends, 90o_{angle bends and other bends are also made on PVC rigid conduit.} In making bends on PVC rigid conduit, the electrician should see to it that the internal diameter of the conduit is not reduced and damaged so that the capacity of the conduit to accommodate maximum number of conductors will not be lessen and to facilitate easy pulling of conductors.

Since PVC conduits are somewhat easier to bend than a rigid conduit, it likewise requires patience as in any other type of conduit. It is first pre-heated over a fire or a heat gun to a desired softness. Little by little, it is bent to its desired shape. When such is attained, it is then hardened by soaking it to cold or lukewarm water or dampened with a wet rag.

1. Elbow

2. Offset bend is less than 90o bend, it is used when the conduit crosses an obstacle or when the conduit is entering an electrical box.

3. Round saddle bend is used when the conduit run across circular objects like pipes.

4. Square saddle bend is similar to round saddle, it is used when the conduit run across rectangular obstacles. Square saddle is just a combination of two offset bends.

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Bend Defects

1. Burned

2. Kinks or groove

3. The diameter of the conduit is greatly reduced due to improper bending procedure.

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OPERATION SHEET 3.1 Bending 90o_{PVC Elbow} Tools, Materials and Equipment Needed

Equipment:

 Heat gun - 1 unit

Materials:

 Pencil or Chalk - 1 pc

 PVC pipe - 1 m

Tools:

 Steel meter stick/Straight edge - 1 pc

 Try square - 1 pc

 Pull and push rule - 1 pc

 Wet rug - 1 pc

Personal Protective Equipment:

 Gloves - 1 pair

 Respirator - 1 pc

Procedure:

Instruction: When you are ready to perform this task, ask your teacher to observe the process and to rate your performance using the assessment criteria.

1. Prepare the necessary tools, materials and equipment. 2. Wear appropriate PPE.

Note: The greatest danger comes from vinyl chloride, a primary component of polyvinylchloride (PVC) and an odorless gas which could be released using this process. Vinyl Chloride is a toxic carcinogen which has been proven to cause angiosarcoma, a deadly primary liver cancer. Use a good respirator and adequate ventilation to protect yourself from this toxin.

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3. Draw a right angle on the floor using your try square and chalk. This will serve as your guide when forming your conduit into 90o_{angle. (A} tile on the floor can serve as a guide.)

4. If you are in a room with a tiled floor, you can use it as your guide for 90o_angle.

5. Draw an arc near the corner with a radius of 100 mm; this will aid you in forming your elbow correctly.

Note: 20 mm diameter of PVC should have a radius of 100 mm as mentioned in the previous information sheet.

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6. Mark off 200 mm from the end of PVC pipe. This will be the center of your elbow bend.

7. Plug-in the heat gun and apply heat to the conduit. Apply heat 100mm on both sides of your marking. Apply heat evenly by turning over the conduit while swaying your heat gun back and forth to avoid kinks during bending.

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9. If the conduit is soften, turn off the heat gun and bend the PVC to the desired shape using your arc and 90o_{angle guide drawn on the floor.}

10. If the desired shape is formed, damp the conduit with wet rug to harden it immediately. (You can use your foot to hold one end of the conduit while wiping.)

11. Perform housekeeping. Assessment Criteria

1. Quality: Workmanship, Appearance, Bending 90°, 2. Accuracy: Dimension, Accurate bending

3. Method: Observance of the safety measures.

4. Speed: Submission on time +1, before the expected time +2, after the expected time – 2.

Rating Scale:

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OPERATION SHEET 3.2 PVC Offset Bending Tools, Materials and Equipment Needed

Equipment:

 Heat gun - 1 unit

Materials:

 Pencil or Chalk - 1 pc

 PVC pipe - 1 m

Tools:

 Steel meter stick/Straight edge - 1 pc

 Try square - 1 pc

 Pull and push rule - 1 pc

 Wet rug - 1 pc

 Gloves - 1 pair

 Respirator - 1 pc

Procedure:

1. Prepare the necessary tools, materials and equipment. 2. Wear appropriate PPE.

Respirator Gloves

3. Measure the elevation of the obstruction. In this case, let’s use this wooden box.

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Note: Remember, offset bent is used if the conduit crosses an obstruction. In this case, the elevation is about 70 mm.

4. Draw the depth of elevation on the floor as shown in the figure using your try square and chalk. This will guide you how high your offset bend would be.

5. You should have two lines as shown in the figure.

6. Mark off 100 mm from the end of PVC pipe. This will be the center of the first bend of the offset.

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7. Put another mark of about 200 mm from your first marker.

8. Plug-in the heat gun and apply heat to the conduit. Apply heat between your markers. Apply heat evenly by turning over the

conduit while swaying your heat gun back and forth to avoid kinks during bending.

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9. If the conduit is soften, turn off the heat gun and bend the PVC to the desired shape using your guide drawn on the floor. Pull the left portion of the conduit while pushing the other end.

10. If the desired shape is formed, damp the conduit with wet rug to harden it immediately. (You can use your foot to hold one end of the conduit while wiping.)

11. Your bend should look like this.

1. Quality: Workmanship, Appearance, Offset Bending 2. Accuracy: Dimension, Accurate bending

Rating Scale:

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JOB SHEET 3.1

Install rigid non-metallic conduit

Install two bulbs controlled by two (2) three-way switches and one (1) SPST switch with two convenience outlet.

Please refer to the Learning Outcome No. 2. Layout and Install PVC raceway/molding for the important PEC provisions in installing rigid non-metallic conduit and personal safety

TOOLS, EQUIPMENT AND MATERIALS Equipment:

 Heat gun 1 unit

Materials:

 Pencil or Chalk 1 pc

 PVC pipe 3 pcs

 PVC adapter with lock nuts 18 pcs

 Utility box 5 pcs  Junction box 4 pcs  Lamp socket 2 pcs  Safety switch 1 pc  3 way switch 2 pcs  SPST switch 1 pc

 1 gang plate cover 3 pcs

 2 gang plate cover 2 pcs

 Conduit clamps/straps 15 pcs  Wood screws (1/4 x ½) 50 pcs Tools:

 Steel meter stick/Straight edge 1 pc

 Try square 1 pc

 Pull and push rule 1 pc

 Wet rug 1 pc

 Gloves 1 pair

 Respirator 1 pc

Procedure:

1. Prepare the necessary tools, materials and equipments. 2. Wear appropriate PPE.

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3. Mark on the wiring board the location of the safety switch, utility boxes, and junction boxes.

4. Fasten the safety switch and PVC boxes with wood screws at the desired locations.

5. Prepare the PVC conduit for installation.

a. Measure and cut each PVC pipe to desired length

b. Make an offset bend at each end of PVC conduit which will be connected to a box.

c. Bend 90º based on the diagram.

6. Install and connect ends of PVC pipe to the electrical boxes, safety switch.

7. Support the conduit with conduit clamps or straps.

8. Place the cover of junction box, utility box, and convenience outlet. 9. Perform good house keeping.

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10. Have your teacher check your work.

Note: Your teacher will determine the distance of each circuit.

Line diagram of the two bulbs controlled by two (2) three-way switches and one (1) SPST switch with two convenience outlets in different location.

1. Quality: Workmanship, Appearance, Offset Bending, Bending 90º

2. Accuracy: Dimension, Accurate bending 3. Method: Observance of the safety measures.

Rating Scale:

S S3w

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Learning Outcome 4: Layout and install flexible non-metallic conduit. Assessment Criteria:

1. PEC provisions in installing flexible non-metallic conduit are strictly followed.

2. Uses and application of flexible non-metallic conduit are discussed according to the PEC.

3. Electrical flexible non-metallic conduits are leveled horizontally and vertically aligned to the structure specified in job requirements.

4. Workplace is cleaned and made safe upon the completion of work according to the established standard.

5. Tools, materials and equipments needed for the installation are prepared in line with job requirements.

6. Flexible non-metallic conduit is installed in line with job requirements.

7. Flexible non-metallic conduit is installed in line with the job requirements

8. Final report is prepared upon the completion of job. References:

1. Johnston, Larry et.al., Better Homes and Gardens Wiring 1st_Edition, Meredith Books; 2007,pp.

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LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome 4: Layout and install flexible non-metallic conduit. Learning Activities Special Instructions

1. Read Information sheet 4.1 about the flexible metal conduit.

 You can ask assistance from your teacher to show you and explain furtherly the topic you cannot understand well.

2. Perform activity sheet 4.1 on how to install conduit and electrical wiring from indoor unit to outdoor unit using flexible nonmetallic tubing

 Teacher will supervise your activity in installing of flexible nonmetallic tubing.

3. Answer the Self-check 4.1  Check your answer by using the answer key.

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INFORMATION SHEET 4.1 Flexible Nonmetallic Conduit

This portion of information sheet is lifted from Philippine Electrical Code, 2000, Part I.

Definition. Liquid tight flexible nonmetallic conduit is a listed raceway of circular cross section of various types as follows: 1. A smooth seamless inner core and cover bonded together and having

one or more reinforcement layers between the core and cover designated as Type LFNC-A.

2. A smooth inner surface with integral reinforcement within the conduit wall, designated as Type LFNC-B.

3. A corrugated internal and external surface without integral reinforcement within the conduit wall, designated as Type LFNC-C. This conduit is flame resistant and, with fittings, is approved for the installation of electrical conductors.

Uses.

(a) Permitted. Listed liquid tight flexible nonmetallic conduit shall be permitted to be used in exposed or concealed locations for the following purposes. FPN: Extreme cold may cause some types of nonmetallic conduits to become brittle and therefore more susceptible to damage from physical contact.

(1) Where flexibility is required for installation, operation, or maintenance.

(2) Where protection of the contained conductors is required from vapors, liquids, or solids.

(3) For outdoor locations where listed and marked as suitable for the purpose. FFN: For marking requirements, see Section 110.1.21

(4) For direct burial where listed and marked for the purpose.

(5) Liquid tight flexible nonmetallic conduit as defined in Section 3.51.2.1(2) shall be permitted to be installed in lengths longer than 1 800 mm where secured in accordance with Section 3.51.2.6.

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(6) As a listed manufactured prewired assembly, 15, mm (20mm) through 25 mm (32 mm) conduit, as defined in Section 3.51 .2.1(2).

(b) Not Permitted. Liquid tight flexible nonmetallic conduit shall not be used in the following:

(1) `Where subject to physical damage

(2) Where any combination of ambient and conductor temperature is in excess of that for which the liquid tight flexible nonmetallic conduit is approved

(3) In lengths longer than 1 800 mm, except as permitted by Section 3.51 .2.2(a)(5) or where a longer length is approved as essential for a required degree of flexibility.

(4) Where voltage of the contained conductors is in excess of 600 volts, nominal

Exception. As permitted in Section 6.0.2.3(a) for electric signs over 600 volts.

Size. The electrical trade sizes of liquid tight flexible nonmetallic conduit shall be in accordance with (a) or (b):

(a) 15mm (20 mm) to 100mm (110mm) inclusive (b) 10 mm (15 mm) as permitted below

(1) For enclosing the leads of motors as permitted in Section 4.30.13.5(b) (2) In lengths not exceeding 1 800 mm as part of a listed assembly for tap connections to lighting fixtures as required in Section 4.10.13.4(c), or for utilization equipment (3) for electric sign conductors in accordance with Section 6.0 .2 .3 (a)

Number of Conductors. The number of conductors permitted in a single conduit shall be in accordance with the percentage fill specified.

Fittings. Liquid tight flexible non - metallic conduit shall be used only with listed terminal fittings. Angle connectors shall not be used for concealed raceway installations.

Securing and Supporting. Liquid tight flexible nonmetallic conduit, as defined in Section 3.51.2.1(2), shall be securely fastened and supported in accordance with one of the following.

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(a) The conduit shall be securely fastened at intervals not exceeding 900 mm and within 300 mm on each side of every outlet box, junction box, cabinet, or fitting.

(b) Securing and supporting of the conduit shall not be required where it is fished, installed in lengths not exceeding 900 mm at terminals where flexibility is required, or where installed in lengths not exceeding 1 800 mm from a fixture terminal connection for tap conductors to lighting fixtures as permitted in Section 4.10.13.4(c)

(c) Horizontal runs of liquid tight flexible nonmetallic conduit supported by openings through framing members at intervals not exceeding 900 mm and securely fastened within 300 mm of termination points shall be permitted.

3.51.2.7 Equipment Grounding. When an equipment grounding conductor is required for the circuits installed in liquid tight flexible nonmetallic conduit, it shall be permitted to be installed on the inside or outside of the conduit. When installed on the outside, the length of the equipment grounding conductor shall not exceed 1 800 mm and shall be routed with the raceway or enclosure. Fittings and boxes shall be bonded or grounded in accordance with Article 2.50.

Splices and Taps. Splices and taps shall be made in accordance with Section 3.0.1 13. See Article 3.70 for rules on the installation and use of boxes and conduit bodies.

Bends-Number in One Run. There shall not be more than the equivalent of four quarter bends (360 degrees total) between pull points, e.g., conduit bodies and boxes.

Flexible Nonmetallic Conduit Fittings

Coupling

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Adapter

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Job Sheet 4.1

Install conduit and electrical wiring from indoor unit to outdoor unit using flexible nonmetallic tubing.

Tools, Materials and Equipment Needed

Equipment:

o *Electric drill - 1 unit

Materials:

o Pencil or Chalk - 1 pc

o Installation plan or working drawing - 1 pc o Flat head screw, ¾ in X 10 - 15 pcs

o *Fisher, # 6 (Tox) - 15 pcs

o Flexible nonmetallic tubing - 5 m

o Mica tube, ¼ in. dia. - 1 m

o Stranded wire, 2.0 mm2 _TW _-

o Safety switch, 30 A -

Tools:

o Pull and push rule or any measuring

device suited for the activity - 1 pc o Steel meter stick/Straight edge - 1 pc

o Safety glass - 1 pc

o Gloves - 1 pair

o Goggles - 1 pc

o Safety shoes - 1 pair

Introduction:

In installing electrical circuit, you may use any type of approved wiring method for the purpose. It has been a practice in this field to use flexible nonmetallic tubing because flexibility is required for installation, operation, and maintenance. You may use rigid nonmetallic conduit (PVC) as taught in the previous instruction sheets.

Procedure

1. Wear appropriate PPE

2. Measure the required length of flexible nonmetallic conduit from the outdoor unit to the indoor unit. You may use any measuring device suited for the job or you may use the actual material by practically tracing its path as shown in the picture.

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3. Cut the flexible nonmetallic tubing.

4. Insert the wires first before laying out the tubing permanently.

5. Use guide wires to facilitate easy pulling of conductors. Use galvanized iron wire, gauge 14 AWG. Insert it at one end of the tubing until it reaches the other end of the tubing.

6. Prepare the required length of the conductor. It may be as long as the length of the tubing plus an ample allowance at both ends for splicing. Then mark off the conductors at both ends to distinguish them from each other.

Note: Allowance must be at least 150 mm long at both ends measured from the ends of the tubing.

You may use electrical tape or masking tape in marking off the conductors

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7. Tie the conductors securely to the guide wires.

8. Pull the guide wires at the other end of the tubing. The tubing should be laid straight forward for easy pulling of conductors.

9. Seek assistance from other person. The conductors should be push from the other end while being pulled from the other end.

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10. Lay out the tubing with conductors permanently.

11. Just simply lay the electrical tubing on the path where the refrigeration system tubing is installed.

12. Secure the flexible nonmetallic tubing wrapping it with cable tie.

13. Insert the connector. Wire allowance

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14. Secure the tubing to the raceway on the indoor unit.

15. Put the lock nut and tighten it.

16. Prepare the conductor for termination. Strip off at least 5 mm of insulation.

17. Terminate the conductors. It is indicated in the manufacturer’s manual how to terminate the conductors.

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18. Be sure that the connections are tightened correctly.

19. You have just finished the electrical circuit from indoor to outdoor unit. Now, you are ready for the installation of the main power supply. The main supply line is usually pre-wired by the manufacturer, you have to do is to terminate it from the circuit protection.

20. Terminate to the circuit protection.

21. Test the circuit for ground short or open wiring. If fault is found, rectify it.

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22. Turn on the circuit and test run the unit.

23. Perform housekeeping

Dimensions VS S NI

1. Quality: Quality, workmanship, appearance

2. Accuracy: Dimension, horizontality and verticality of conduits

Rating Scale:

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SELF-CHECK 4.1

Direction: Label the different types of Flexible Nonmetallic Conduit

Fittings. Write your answer on a separate answer sheet.

1.

2.

3.

4.

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Unit of Competency : INSTALL ELECTRICAL LIGHTING SYSTEM ON THE AUXILIARY OUTLETS AND LIGHTING FIXTURES

Module Title : Installing of Electrical Lighting System on the Auxiliary Outlets and Lighting Fixtures

Learning Outcome 5: Assemble fluorescent lighting fixtures. Assessment Criteria:

1. Fluorescent lighting fixtures are identified and described according to the specification.

2. Parts and function of fluorescent fixtures are explained.

3. Sizes, shapes and ratings of fluorescent lighting fixtures are identified and described.

4. Schematic diagram of fluorescent lighting fixtures is interpreted.

5. Tools, instruments and materials are selected in line with job requirements.

6. Fluorescent lighting fixtures are assembled in line with job requirements.

7. Fluorescent lighting fixtures are wired according to the schematic diagram.

8. Workplace is cleaned and made safe upon the completion of the job References:

1. Johnston, Larry et.al., Better Homes and Gardens Wiring 1st_Edition, Meredith Books; 2007,pp.

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LEARNING EXPERIENCES/ACTIVITIES

Learning Outcome 5: Assemble fluorescent lighting fixtures.

1. Read Information sheet 5.1

of this module  You can ask assistance from your teacher to show you and explain further topic you can’t understand.

2. Perform Job Sheet 5.1 in Assembling Open type 20 watts Fluorescent Lamp

 The teacher supervises while you perform the activity.

3. Perform Job Sheet 5.2 in Assembling 40 watts

Fluorescent fixture using 2 x 40 watt high power

factor (H.P.F.) ballast

4. Perform Job Sheet 5.3; in Assembling two unit 40 watts Fluorescent fixture using rapid start ballast

5. Perform Job Sheet 5.1; in Assembling Fluorescent lighting fixtures

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INFORMATION SHEET 5.1 Fluorescent lighting fixtures

Fluorescent Lamp –is a form of electric discharge light source. It consists of a glass tube containing mercury vapor at a low pressure and inert gas like argon and krypton. The interior is coated with phosphor, which glows or fluoresces when exposed to ultraviolet light.

PEC Rules on Wire Dressing and Termination

Article 6.3.1.3 Live Parts. Fixtures, lamp holders, lamps, rosettes, and

receptacles shall have no live parts normally exposed to contact. Exposed accessible terminals in lamp holders, receptacles, and switches shall not be installed in metal fixture canopies or in open bases of portable table or floor lamps.

All joints/splices to be done must be properly insulated with spaghetti sleeving, wrapped with electrical tape having a similar thickness of the conductor used.

Types of electric discharge fluorescent lamps

1. Pre-heat starting, hot-cathode –requires starter (glow switch) and is pre-heated during starting. It uses a ballast to produce high voltage to start the lamp into operation and to limit the flow of current.

2. Cold cathode – Requires high voltage in its operation. This lamp has electrodes made of thimble-type iron. It is not pre-heated and does not require a starter for starting. Special high voltage transformers operate it. Neon and mercury lamps are classified under cold cathode lamps.

3. Instant-starting, hot-cathode –The lamp cathode in the instant-start is not pre-heated. Sufficient voltage is applied across the cathodes to create an instantaneous arc. As in preheat circuit; the cathodes are heated during lamp operation by the arc. The instant-start lamp require single-pin bases, are generally called slim line lamps.

4. Hot-cathode, rapid-start –These are similar in construction to the preheat lamps; the basic difference is in the circuitry. This circuit eliminates the delay inherent in preheat circuits by keeping the lamp cathodes constantly energized (preheated). When the lamp circuit is energized, the arc is struck immediately. No external starter is required. Because of this similarity of operation, rapid start lamps will operate satisfactorily in a preheat circuit. The reverse is not true, because preheat requires more current to heat the cathode than the rapid-start ballast provides.

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Operation of pre-heat type fluorescent lamp

The tube filaments, starter (glow switch), and ballast are all connected in series, which constitute a complete circuit once the switch, is closed. As a current flow through, the gas (inert) inside the starter glows and the electrodes are heated. Since one of the electrodes is a bi-metal, it bends and makes contact with the other. At this instant, the circuit is metallically complete. The filaments of the fluorescent tube are then heated and partial ionization takes place. The bi-metals in the starter cools and the contacts open. The magnetic field in the ballast collapses rapidly producing an inductive kick, which establishes a current between the filaments and fires the tube into operation.

Classifications of Fluorescent Lamp 1. Regular Fluorescent Lamp

Circular type fluorescent lamp

Open type fluorescent

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2. Compact Fluorescent Lamp

Different types of Compact Fluorescent Lamp Parts and functions of fluorescent lamp

1. Fluorescent tube is a circular bulb containing mercury vapor and inert gas with phosphor coating inside.

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Parts of Fluorescent tube

1. Ballast is an induction coil, which produces high voltage to start the lamp into operation. It also limits the flow of current during the operation of the lamp. Ballast consumes power, which is between 10-20% of power consumed by the lamp itself.

Different types of Ballast

2. Starter is a glow switch that opens and closes the circuit so as to produce a high voltage or inductive kick across the bulb at the filament during the starting period.

Electronic type ballast Induction type ballast

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Different types of Starter

3. Lamp holder and starter socket are the point of connection of the fluorescent and starter.

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Parts of fluorescent lamp starter

Current moves in utilizing the rare gas as conducting means and the rare gas produces a “glow”. The glow generates heat and causes the bimetallic blade to expand.

When the bimetallic blade is heated, it changes shape and touches the fixed contact. The close contacts of the two starter contacts produce an easy path for the current to flow.

Parts and operation function of the ballast

Starter housing

Base contact Connecting

wire

Ballast frame

Laminated iron core

Terminal block

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In common with all gaseous discharge lamps, the fluorescent must be provided with some device for limiting the current drawn by the discharge. Without a limiting device, the current would rise to a value that would destroy the lamp. A device or auxiliary called ballast can best meet this requirement.

The ballast for operating lamps on an alternating current consists of a small choke coil woven on an iron core.

This ballast serves three important functions:

1. It preheats the electrodes to make available a large supply of the electron.

2. It provides a surge of relatively large potential to start the arc between the electrodes.

3. It prevents the arc current to increase beyond the limit set for each size and lamp.

THE LIFE SPAN OF FLUORESCENT LAMP

The life of fluorescent lamp is affected not only in the fluctuation of voltage and current but also by the number of times it is started. Electron emission material is “sputtered off” from the electrodes continuously during the operation of the lamp and in larger quantities each time the lamp starts.

Many fluorescent lamps have a rated average life span up to 30,000 continuous burning hours but with an average of 3 hours burning per start, it could only last for 12,000 hours.

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JOB SHEET 5.1

Assembling Open - type 20 watts Fluorescent Lamp Tools, Materials Needed

Material:

 Fluorescent Lamp (20 watts) - 1 set

Tools:

 Philip Screw driver - 1 pc

 Flat Screw driver - 1 pc

 Side cutting pliers - 1 pc

 Long nose pliers - 1 pc

 Gloves - 1 pair

 Goggles - 1 pc

Procedures:

1. Prepare the necessary tools, materials. 2. Wear appropriate PPE.

3. Assemble and wire a 20-w fluorescent fixture using Normal or Medium Power Factor ballast (M.P.P)

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Use bolt and nut in fixing the ballast to the frame 4. Mount the starter socket to the frame. Make sure it is attached

securely.

5. Mount the connection terminal socket to the frame. Make sure that it is fixed not too loose or too tight.

6. Make the necessary connections of the fluorescent fixture by referring to the schematic wiring diagram.

Electricity Y3

1

ACKNOWLEDGMENT

TABLE OF CONTENTS

HOW TO USE THIS MODULE

Recognition of Prior Learning (RPL)

TECHNICAL TERMS

LEARNING EXPERIENCES/ACTIVITIES

INFORMATION SHEET 1.1

LEARNING EXPERIENCES/ACTIVITIES

INFORMATION SHEET 2.1

LEARNING EXPERIENCES/ACTIVITIES

JOB SHEET 3.1

LEARNING EXPERIENCES/ACTIVITIES

LEARNING EXPERIENCES/ACTIVITIES