Performing Engineering

Operations
QPEO2/033N
Credit Value: 14 QCF Level: 2 GLH: 64
Wiring and testing electrical equipment and
circuits
Learner Name: ……………………………

EAL Assessment Route Summary

This EAL assessment route covers the skills and knowledge needed to prove the competences required to wire up and test
electrical equipment and circuits. It will prepare the learner for entry into the engineering or manufacturing sectors, creating a
progression between education and employment, or it will provide a basis for the development of additional skills and
occupational competences in the working environment.
The activities will include the wiring and termination of a range of cables, such as single and multicore cables, screened cables,
fire resistant and armoured cables. The learner will be required to make a variety of terminations and to connect a range of
electrical components, such as switches/switchgear, distribution panels, motors and starters, control systems, sensors and
actuators, safety devices, and luminaires.
The learner will be required to select the appropriate tools, materials and equipment to use, based on the operations to be
performed and the components to be connected. The learner will be expected to use appropriate tools and techniques for the
wiring of the various electrical components and connectors that make up the electrical system/circuit. In addition, the learner
will be expected to make all necessary electrical connections to the switches, relays, sensors/actuators and other devices, as
appropriate to the equipment and circuit being produced. The wiring and testing activities will include making all necessary
checks and adjustments to the circuit, including continuity, polarity, insulation resistance values, and ensuring that the
equipment functions to the specification.
The learner’s responsibilities will require them to comply with health and safety requirements and organisational policy and
procedures for the wiring and testing activities undertaken. The learner will need to take account of any potential difficulties or
problems that may arise with the wiring and testing activities, or with the tools and equipment used, and to seek appropriate
help and advice in determining and implementing a suitable solution. The learner will work under a high level of supervision,
whilst taking responsibility for their own actions and for the quality and accuracy of the work that they carry out.
The learner’s knowledge will provide an understanding of their work, and will enable them to apply appropriate electrical wiring
and testing procedures and techniques safely. The learner will understand the wiring and testing methods and procedures used,
and their application, and will know about the various cables and components used to produce the circuits, to the required depth
to provide a sound basis for carrying out the activities to the required specification.
The learner will understand the safety precautions required when carrying out the wiring and testing activities, especially
those for ensuring the safe isolation of the equipment and circuits produced. The learner will be required to demonstrate safe
working practices throughout, and will understand the responsibility they owe to themselves and others in the workplace.
NOTE: Pre 16 Learners
It is a requirement of the EAL qualification that ALL teaching and assessment staff are fully competent and can provide evidence
of their competence in the technical and health and safety requirements of the specific technical units chosen; such as
machining, electrical and electronic, welding and fabrication for delivery/ assessment of pre 16 learners to enable the learner to
safely meet the required standards. Centres approved to deliver this PEO qualification must ensure that ALL pre 16 learners are
safeguarded at all times. The higher the risk activities within the technical units require supervision at all times and can only be
delivered within a secure environment
Specific additional performance assessment requirements:
In order to prove their ability to combine different electrical assembly and wiring activities, at least one of the electrical
assemblies produced must be of a significant nature, and must contain a minimum of five of the components listed in
assessment criteria 10 plus five of the activities listed in assessment criteria 13.

© 2013 Excellence, Achievement & Learning Ltd

 Wiring and testing electrical equipment and
circuits
Performance Learning outcomes – the learner will…
Wire and test electrical equipment and circuits

Assessment criteria - the learner can…

(Performance to be assessed and evidenced) Reference

1. Work safely at all times, complying with health and safety legislation, regulations and
other relevant guidelines

2. Carry out all of the following activities during the wiring and testing activities:
a) adhere to procedures or systems in place for risk assessment, COSHH, personal
protective equipment (PPE) and other relevant safety regulations
b) ensure the safe isolation of services during the wiring and testing activities
c) follow job instructions, circuit drawings and test procedures at all times
d) check that tools and test instruments to be used are within calibration date, and
are in a safe and usable condition, including PAT tested
e) ensure that the electrical system is kept free from foreign objects, dirt or other
contamination
f) where appropriate, apply procedures and precautions to eliminate electrostatic
discharge (ESD) hazards
g) return all tools and equipment to the correct location on completion of the wiring
and testing activities

3. Wire up three of the following electrical systems:

a) domestic lighting circuits
b) domestic power circuits
c) motor start and control
d) vehicle heating or ventilating
e) vehicle lighting
f) vehicle starting and ignition
g) instrumentation and control circuits
h) alarm systems (such as fire, intruder, process control)
i) electro-pneumatic or electro-hydraulic control circuits
j) other control circuits (such as pumps, fans, blowers, extractors)
k) air conditioning control circuits
l) refrigeration control circuits
m) heating/boiler control circuits
n) aircraft lighting circuits
o) power generation and control circuits
p) avionic circuits and systems
q) emergency lighting systems
r) communication systems
s) computer systems
t) other specific electrical circuits

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4. Plan the wiring and testing activities before they start them

5. Use appropriate sources to obtain the required specifications, circuit diagrams and test
information

6. Obtain the correct tools and equipment for the wiring and testing operations, and check
that they are in a safe and usable condition

7. Use two of the following test instruments during the wiring and testing activities:
a) multimeter
b) insulation resistance tester
c) polarity tester/indicator
d) RCD tester
e) earth-loop impedance tester
f) other specific test equipment

8. Mount and secure the electrical components safely and correctly, to meet specification
requirements

9. Wire circuits using three of the following types of cables:

a) single core
b) multicore
c) PVC twin and earth
d) flexible (such as cotton or rubber covered)
e) data/communication
f) fibre-optics
g) screened
h) coaxial
i) ribbon cables
j) mineral insulated
k) armoured
l) wiring loom/harness

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10. Connect up ten of the following electrical modules/components to produce circuits:
a) isolators
b) switches
c) sockets
d) contactors
e) motor starters
f) solenoids
g) relays
h) alarm devices
i) motors
j) pumps
k) heaters
l) blowers
m) lamp holders
n) panel lamps
o) luminaires
p) ballast chokes
q) consumer units
r) residual current device (RCD)
s) instruments
t) transformers
u) panels or sub-assemblies
v) control devices
w) cable connectors
x) fuses
y) circuit breakers
z) sensors
aa) actuators
bb) junction boxes
cc) terminal blocks
dd) electronic modules/units
ee) other electrical components

11. Install and terminate the cables to the appropriate connections on the components

12. Apply wiring methods and techniques to include six of the following:
a) positioning and securing of equipment and components
b) levelling and alignment of components
c) determining current rating and lengths of cables required
d) securing by using mechanical fixings (such as screws, nuts and bolts)
e) laying in cables without twisting or plaiting
f) feeding cables into conduit without twisting or plaiting
g) leaving sufficient slack for termination and movement

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 Wiring and testing electrical equipment and
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13. Carry out eight of the following cable termination activities:
a) stripping cable sheaths without damage to conductor insulation
b) removing cable insulation
c) connecting accessories (such as plugs, sockets multi-way connectors)
d) making mechanical/screwed/clamped connections
e) crimping (such as spade end, loops, tags and pins)
f) soldering and de-soldering
g) terminating armoured cables
h) terminating mineral insulated cables
i) sealing/protecting cable connections
j) attaching suitable cable identification
k) securing wires and cables (such as clips, plastic strapping, lacing, harnessing)
l) heat shrinking (devices and boots)
m) earth bonding
n) cable glands and grips

14. Use appropriate test methods and equipment to check that the completed circuit is safe
and meets all aspects of the specification

15. Carry out checks and adjustments, appropriate to the equipment and circuits being wired,
to include three of the following:
a) making visual checks (such as completeness, signs of damage, incorrect
termination)
b) movement checks (such as loose fittings and connections)
c) testing that the equipment operates to the circuit specification
d) carrying out fault finding techniques (such as half-split, input/output, unit
substitution)
Plus three more from the following:
e) protective conductor resistance values
f) insulation resistance values
g) continuity
h) voltage levels
i) load current
j) polarity
k) resistance
l) capacitance
m) power rating
n) frequency values
o) inductance
p) RCD disconnection time
q) specialised tests (such as speed, sound, light, temperature)

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16. Produce electrical circuits in accordance with one or more of the following standards:
a) BS 7671/IET wiring regulations
b) other BS and/or ISO standards
c) company standards and procedures

17. Deal promptly and effectively with problems within their control, and seek help and
guidance from the relevant people if they have problems that they cannot resolve

18. Leave the work area in a safe and tidy condition on completion of the wiring and testing
activities

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 Wiring and testing electrical equipment and
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Knowledge Learning outcomes – the learner will…
Know how to wire and test electrical equipment and circuits

Assessment criteria - the learner can…

(Knowledge to be assessed and evidenced)

1. Describe the specific safety practices and procedures that they need to observe when wiring
and testing electrical equipment (including any specific legislation, regulations or codes of
practice for the activities, equipment or materials)

2. Describe the hazards associated with wiring and testing electrical equipment, and with the tools
and equipment used, (such as using sharp instruments for stripping cable insulation), and how
they can be minimised

3. Describe the importance of wearing appropriate protective clothing and equipment (PPE), and
keeping the work area safe and tidy

4. Explain what constitutes a hazardous voltage and how to recognise victims of electric shock

5. Explain how to reduce the risks of a phase to earth shock (such as insulated tools, rubber
mating and isolating transformers)

6. Describe the interpretation of circuit diagrams, wiring diagrams, and other relevant
specifications (including BS and ISO schematics, wiring regulations, symbols and terminology)

7. Describe the basic principles of operation of the equipment/circuits being produced, and the
purpose of the individual modules/components used

8. Describe the different types of cabling and their application (such as multicore cables, single
core cables, solid and multi-stranded cables, steel wire armoured (SWA), mineral insulated (MI),
screened cables, data/communications cables, fibre-optics)

9. Describe the application and use of a range of electrical components (such as plugs, switches,
sockets, lighting and fittings, junction boxes, consumer units, relays, solenoids, transformers,
sensors and actuators)

10. Describe the application and use of circuit protection equipment (such as fuses and other
overload protection devices, trips, residual current device (RCD))

11. Explain how to check that components meet the required specification/operating conditions
(such as values, tolerance, current carrying capacity, voltage rating, power rating, working
temperature range)

12. Describe the methods of mounting and securing electrical equipment/components to various
surfaces (such as the use of nuts and bolts, screws and masonry fixing devices)

13. Explain how to check that the positions selected for mounting the components do not interfere
with or damage existing services (such as cable harnesses, pipework or electricity supplies)

14. Describe the methods of laying in or drawing cables into conduit, trunking and traywork
systems, and the need to ensure the cables are not twisted or plaited

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15. Describe the techniques used to terminate electrical equipment (such as plugs and sockets;
soldering; screwed, clamped and crimped connections, glands and sealed connectors)

16. Describe the use of BS7671/IET wiring regulations when selecting wires and cables and when
carrying out tests on systems

17. Describe the methods of attaching markers/labels to components or cables to assist with
identification (such as colour coding conductors, using coded tabs)

18. Describe the tools and equipment used in the wiring and testing activities (including the use of
cable stripping tools, crimping tools, soldering irons and torches, gland connecting tools)

19. Explain how to check that tools and equipment are free from damage or defects, and are in a
safe, PAT tested, calibrated and usable condition

20. Describe the importance of conducting inspections and checks before connecting to the supply
(such as visual examination for loose or exposed conductors, excessive solder or solder spikes
which may allow short circuits to occur, strain on terminations, insufficient slack cable at
terminations, continuity and polarity checks, insulation checks)

21. Describe the care, handling and application of electrical test and measuring instruments (such
as multimeter, insulation resistance tester, loop impedance test instruments)

22. Explain how to apply approved test procedures; the safe working practices and procedures
required when carrying out the various tests, and the need to use suitably fused test probes and
clips

23. Explain how to identify suitable test points within the circuit, and how to position the test
instruments into the circuit whilst ensuring the correct polarity and without damaging the
circuit components and the test equipment

24. Explain how to set the instrument’s zero readings; obtaining instrument readings and
comparing them with circuit parameters

25. Explain why electrical bonding/earthing is critical, and why it must be both mechanically and
electrically secure

26. Describe the problems that can occur with the wiring and testing operations, and how these can
be overcome

27. Describe the fault-finding techniques to be used if the equipment fails to operate correctly (such
as half split, unit substitution and input/output)

28. Explain when to act on their own initiative and when to seek help and advice from others

29. Describe the importance of leaving the work area in a safe and clean condition on completion of
the wiring and testing activities (such as returning hand tools and test equipment to is
designated location, cleaning the work area, and removing and disposing of waste)

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