ELECTRICAL WINDER
Name of Sector Electrical Name of Module Electrical Winder
Minimum Age 18 Years Duration of Course 6 Months
ADU Code ELE703

Degree in Electrical Engineering with one year Experience

(OR)

Diploma in Electrical Engineering with two year Experience

(OR)

NTC/ NAC in Electrical Trade Group with three years of Experience



BASIC ELECTRICAL

1. State what is an accident, the probable causes and safe attitude.

2 Rescue a person who is in contact with a live wire

3. Understand the general safety of Tools and Equipments.

4. Describe electricity, conductor, insulator, voltage, current, resistance, P.D., and interrelation between Voltage, Current, and Resistance etc.

5. Connect volt meter, watt meter, ammeter, energy meter, multimeter, materials in simple electric circuits and measure the units.

6. Do various connections like series, parallel etc.

7. Explain the difference between AC & DC

8. Describe the purpose of Earthing and Types of Earthing

TRANSFORMER WINDING

9. Dismantle the transformer cores

10. Measure and also determine the size of winding wire for primary and secondary.

11 Take the dimensions of a bobbin and prepare the bobbin from suitable materials.

12 Wind the primary and secondar y winding layer by layer.

13. Stack the cores and fasten them

14. Test the transformer for insulation, transformation ratio and performance

15. Check a fluorescent lamp chock, starter and install it.

ARMATURE WINDING

16. Observe the safety precautions while working.

17. Check and test the armature.

18. Strip the old winding from the armature.

19. Record the winding data.

20. Prepare the armature for rewinding.

21. Wind the coils by hand insulate them.

22. Solder the leads to the commentator raisers.

23. Varnish the armature winding.

24. Understand end connection, electrical and distinguishing start and finish of each.

AC/DC MOTOR WINDING

25. Observe the safety precautions while working.

26. List the materials used for motor winding.

27. Method of stripping the old winding and preparing the winding former and coils.

28. Prepare the winding former and the coils.

29. Wind the coils for starting and running

ELECTRICAL POWER TOOLS

30. Observe the safety precautions while working.

31. The maintenance and troubleshooting techniques of single – phase motors.

32. General maintenance procedures and tests that should be conducted on the main parts.

33. Identify the motor leads that are tagged or color coded according to the standardized color code.

34. Trouble shoots capacitor motors and how to work safely with capacitors in order to avoid electrical shock.

35. Determine which of the specific parts to check when the motor fails to start.

36. Identify the symptoms of trouble in universal motors.

37. Repair of hand drilling machine, marble cutter, heavy duty mini grinder, sander/polishers, blower, heavy duty cutter and portable cutoff saw.

38. Dismantling and reassembling of single phase motor.

39. Use diagnostic table to help in troubleshooting motor in plant



Underpinning Knowledge (Theory) Practical Competencies
    Safety Precaution
  • First aid box
  • Safe handling of stripping/winding tools
  • BIS rules for winding/rewinding


  • Identify different tools for stripping old wire
  • Practice proper and safe use of tools
    Electrical supply system
  • AC single phase and 3-phase supply
  • Difference between single and three phase supply in respect of voltage, current and power


  • Measure/Test single phase supply by multimeter/ test lamp
  • Measure/Test three phase supply by multimeter/ double test lamp
    Introduction to re-winding
  • Types of winding wires
  • Types of insulating materials
  • Insulating materials as per class of insulation (A/E/B/C/F/H)
  • Reasons for insulation failure in electrical machines
  • Terminology used in winding like pole pitch, coil pitch, etc.
  • Method of stripping the old winding
  • Methods of preparing the winding former and the coils.
  • Preparation of winding data as per old winding and rating plate of machine


  • Identify different winding wires
  • Identify different insulating material
  • Test electrical fan/motor for its insulation failure
  • Dismantle electrical fan/motor
  • Identify the damaged/burnt part of winding in fan/motor
  • Prepare the winding former and the coils of different size and shape
  • Record the winding data like size/gauge of wire, number of turns, coil connection, coil pitch, etc.
  • Practice stripping/removing the old winding of fan/motor
    Rewinding procedure of motor
  • Procedure followed for re-winding of all kind ofelectric motors like single phase AC motors, pumpmotors, ceiling fan motors, table fan motors, submersible pump motor, etc.
  • Various methods used of inserting coil into the slots.
  • Preparation of winding table, connection diagram, winding diagram for given Motor
  • Testing for continuity and insulation


  • Prepare insulating paper and wooden / insulating stick as per the slot of motor
  • Prepare the coil as per size, number of turns and coil pitch of the given motor
  • Insert and dress the insulating material in each slot of the motor
  • Insert the coil and mark start/ end point
  • Connect the coils as per connection diagram
  • Test for continuity and winding insulation
  • Assemble the motor and run (without varnishing)
    Varnishing and final test
  • Types of varnishes
  • Methods of impregnation
  • Methods of insulation resistance improvement


  • Practice varnishing of re-winded motor
  • Check the insulation of winding by megger
  • Make proper connections and check the performance of motor
    Rewinding procedure of transformer
  • Basic construction and coil arrangement in primary and secondary side of transformer (single phase & three phase)
  • Concept of turns and voltage ratio
  • Types of wires and strips used for transformer coil
  • Procedure for removing core and coil from transformer tank
  • Methods of testing and general faults in transformer coil
  • Procedure for coil rewinding – hand and motorised coil winding
  • Procedure for placing insulation between coils and core
  • Connection and IR testing of primary and secondary
  • Varnish impregnation and its advantages


  • Measure and determine the size of winding wire/strip for primary and secondary
  • Test and identify the faults in coil of primary and secondary
  • Dismantle the core and coil
  • Repair/ rewind the faulty coils
  • Clean the core and provide suitable insulation
  • Use of hand and motorised coil winding
  • Reassemble the coils of primary and secondary
  • Make connections and test for continuity and IR of primary and secondary
  • Familiarization and operation with the motorized coil winding machine
  • Test the transformer for insulation, transformation ratio and performance
    Armature winding
  • Concept of DC supply
  • Types of armature winding like lap and wave winding
  • Terminology used in armature winding like pole pitch, coil pitch, back and front pitch, progressive and retrogressive winding etc.
  • Method of dismantling the burnt winding wire
  • Preparation of winding data for given armature
  • Procedure for providing insulation, inserting coil and connection to commutator
  • Procedure for securing coil ends on armature
  • Impregnation and testing of armature winding


  • Dismantle the DC motor and identify the parts of armature
  • Check and test the armature
  • Record the winding data and coil connections
  • Strip/remove the armature winding
  • Clean and insert the insulation in the slots
  • Prepare and insert the coil in slots
  • Identify coil ends and make connections to commutator raiser
  • Properly secure/tie the coil ends on the armature
  • Test for continuity and IR of winding
  • Varnish the armature winding
    Repair of electrical power tools
  • Types of electrical power tools as per their application like hand drilling machine, angle grinder, rotary hammer, sander/polisher,blower, heavy duty cutter, portable cut off saw etc.
  • Trouble shooting technique in electrical power tools – like insulation testing, armature defects, field winding, stator winding defects, noisy operation bearing problem, carbon brush changing, turning the commutator surface
  • Methods of preventive and breakdown maintenance


  • Dismantling and reassembling of electrical power tools used like hand drilling machine, angle grinder, rotary hammer, marble cutter, heavy duty mini grinder, sander/polisher, blower, heavy duty cutter, portable cut off saw etc.
  • Trouble shooting in hand tools testing of insulation, armature defects, capacitor testing, carbon brush replacing after bedding – testing the protective devices
  • Practice maintenance of hand tools, overhauling, changing defective parts etc.