Syllabus. For the trade of. Under Apprenticeship Training Scheme In the Informal Sector. Designed in 2002

Transcription

1 Syllabus For the trade of Battery repairer Under Apprenticeship Training Scheme In the Informal Sector Designed in 2002 Government of India Ministry of Labour (D.G.E.&T.) CENTRAL STAFF TRAINING AND RESEARCH INSTITUTE EN Block, Sector V, Salt Lake Kolkata

2 List of Trade Committee Members approved the syllabus for the Trade of Battery Repairer under Apprenticeship Training Scheme in the Informal Sector 1. Shri. H. Somasundaram CSTARI, Kolkata 91. Chairman Director 2. Shri. Arup Dutta Excel Batteries, Kolkata Member 3. Shri. Chittajayee Dutta Excel Batteries, Kolkata Member 4. Shri. R.K. Chakraborty R.D.A.T. (ER), Kolkata Member Training Officer 5. Shri. T. Mukhopadhyay CSTARI, Kolkata Member Dy. Director of Training 6. Shri. S. Kant CSTARI, Kolkata Member Dy. Director of Training 7. Shri. A. Rarhi CSTARI, Kolkata Member Asstt.Directorof Traing 8. Shri. D.K. Saha CSTARI, Kolkata Member Maint. Elect.

3 GENERAL INFORMATION 1. Name of the Trade : BATTERY REPAIRER 2. N.C.O. Code No. : Duration of Apprenticeship Training : 1 year (Including one week Basic Training) 4. Entry Qualification : Passed 10 th class Examination under 10+2 system of Education or its Equivalent. 5. Rebate to Ex-Craftsmen Trainees : Nil. 6. Ratio of Apprentice to Workers : 1 : 2 7. Examination : Practical and Viva Voce at the end of the Training.

4 SYLLABUS FOR THE TRADE OF BATTERY REPAIRER UNDER APPRENTICESHIP TRAINING SCHEME Period of Training : One Year BASIC TRAINING ( ONE WEEK) : 1. Safety precautions as applicable to the trade 2. Hack sawing 3. Tapping 4. Reaming 5. Drilling 6. Fitting & removal of studs 7. Simple soft soldering 8. Brazing TRADE PRACTICAL : 1. Use of insulation testing Megger 2. Use of D.C. Voltmeter, Ammeter Ohmmeter & AVO meter. 3. Soldering or crimpling of cable to lug. 4. Ohm s laws. Resistance., Conductance etc. 5. Practice in Lighting the blow lamp, general care 6. Verification of Faradays Laws of Electrolysis 7. Connection of Voltmeter & Ammeter 8. Safety precautions on the shop floor working 9. Introduction to primary & Secondary cells principles of operations 10. Identification of batteries for correct application 11. Identification of different parts of Storage batteries, cells and their functions. a. Plates b. Electrolyte c. Container i. Bottom grooved support Blocks ii. Connecting bar iii. Terminal/Pillar iv. Vent plug / filler caps v. External connecting strips 12. Initial precautions of Electrolyte filling and initial charging of dry batteries and dry charge batteries. Dilution of Acid/Electrolyte Safety aspects. 13. Maintenance of Battery Topping up with distilled water cleaning terminals & vent plug. 14. Checking voltage, condition of container scaling terminals etc. of batteries.

5 15. Determination of Specific gravity of electrolyte (battery solution) with hydrometer to confirm further serviceability. 16. Battery defects like leakage, cracks, over charging & short circuiting of plates. 17. Recharging batteries on bench charger & by use of fast charger. 18. Over hauling of Batteries. Procedures :- i) Removing all acid from used up batteries ii) Removal of scaling pitch with gas torch iii) Cutting of connecting rods of cells with hacksaw and removal of plates from container. iv) Checking all the parts, cleaning, charging the defective parts and reassembling. 19. Types of plates used in shortage battery cell Faure plates, Plante plates. 20. Measurement of Internal resistance & capacity of a cell 21. Measurement of electrical characteristics of Storage batteries 22. Understanding the symptom/indication of fully charged cell. 23. Dismantling of Ni-Cd batteries& assembling 24. Maintenance procedure, overhauling of different storage batteries. 25. Commissioning of Batteries. Charging & discharging of batteries. Use of HRDT (High rate discharge taster.). 26. Revision and Test. TRADE THEORY : 1. Description, Specification & General care and Maintenance of hand tools just as measuring, assembling and cutting tools, common hand tools. 2. Soldering, its purpose, different percentage of solder, use of flux, different fluxes, different purpose, use of resign, advantage of tinning, description of soldering equipment. 3. Fundamental terms definition, units, elementary electricity, molecule, atom, protons, electrons and neutrons. Common insulating materials uses their description properties. 4. Bond theory, concept of ions 5. Fundamental DC circuits, Ohm s law, Kirchoff s laws, Resistance, Conductance. 6. Theory of Chemical reaction, Electrolysis (Faradays Laws) Electro Chemical equivalent and chemical Equivalent 7. Work power and energy, their relationship, Definition of energy & power, potential difference etc. 8. Knowledge of different types of batteries and purpose of use. 9. Free hand sketching of different shapes of Batteries and its components. 10. Free hand sketching of operations of Electricity flow through resistance and batteries. 11. Instructions regarding various parts of batteries different purpose, care and maintenance. 12. Principle of storage cells Chemical changes on charging and discharging Precautions observed while testing by testing equipment such as hydrometer,

6 voltmeter, High rate discharge cell tester & cadmium stick test. Indication of fully charged batteries. 13. General defects of lead acid battery a) Sulphation, b) Sedimentation, c) Buckling of plates. Ampere hour capacity of battery Process of preparing electrolyte. Special purpose batteries Steel alkaline, zinc silver and motor cycle battery. 14. General maintenance and methods of upkeep of lead acid battery, trickle charging, part of nickel iron or alkaline cell, Chemical changes of charge and discharge. Indications of fully charged battery cell defects and remedies, comparison between lead acid and alkaline cell connection diagrams of charging and lamp charging boards. Types of charging a) constant voltage charging, b). constant current charging, c). safety precautions to be observed while charging the lead acid batteries. 15. Correct method of assembling new batteries, process of lead burning set and gas welding set correct process of testing a battery determination of Internal resistance of lead acid cell. 16. Battery charging circuits, circuit block diagram with components. 17. Polarisation/ or back e.m.f. 18. Internal resistance, Sulphation causes & curses. Trickle charging. 19. Calculation of metal depositing on the basis of atomic weight/chemical equivalent. 20. Calculation of surface areas of metal, cylindrical square, cube etc. 21. Measuring resistance by different methods. 22. Calculation of current, watts, volts of simple electrical circuits. 23. Properties of diodes and function. Types of diodes. 24. Half wave and full wave rectifiers. 25. Grouping of cells-series, parallel, series-parallel. 26. Revision and Test.