Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Digital multimeter | 3-phase motor |
| Phase tester | 3-phase contactor |
| Pliers | Fuse box |
| Set of screwdrivers | Fuses |
| Cable stripper | Thermal overload relay |
| Ball peen hammer | Push buttons (1 NC & 2 NO) |
| Spirit level | 3 Pole Circuit breaker |
| Single pole circuit breaker | |
| Auxiliary relay | |
| Cables 0.75mm2 | |
| Cables R, Y, B 4.0mm2 | |
| Cables R, Y, B 6.0mm2 | |
| Personal Protective Equipment (PPEs) |
| S/N | Item | Quantity |
|---|---|---|
| 1 | 3-phase motor | 1 Pc per Candidate (5 HP, 415V) |
| 2 | 3-phase contactor | 1 Pc per Candidate (415V) |
| 3 | Fuse box | 1 Pc per Candidate |
| 4 | Fuses | 3 Pcs per Candidate |
| 5 | Thermal overload relay | 1 Pc per Candidate (415V) |
| 6 | Push buttons (1 NC & 2 NO) | 1 Set per Candidate |
| 7 | 3 Pole Circuit breaker | 1 Pc per Candidate (C63) |
| 8 | Single pole circuit breaker | 1 Pc per Candidate (C10) |
| 9 | Auxiliary relay | 1 Pc per Candidate |
| 10 | Spirit level | 1 Pc per Candidate |
| 11 | Ball peen hammer | 1 Pc per Candidate |
| 12 | Digital multimeter | 1 Pc per Candidate |
| 13 | Phase tester | 1 Pc per Candidate |
| 14 | Pliers | 1 Set per Candidate |
| 15 | Set of screwdrivers | 1 Set per Candidate |
| 16 | Cable stripper | 1 Pc per Candidate |
| 17 | Cables 0.75mm2 | 5 meters per Candidate |
| 18 | Cables R, Y, B 4.0mm2 | 5 meters per Candidate |
| 19 | Cables R, Y, B 6.0mm2 | 3 meters per Candidate |
| 20 | Personal Protective Equipment (PPEs): Safety boots, Overall, Gloves, Safety helmet | 1 Set per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Observed occupational health and safety compliance | |||
| Worn safety boots (Award 1 mark for correct PPE) | 1 | ||
| Worn overall (Award 1 mark for correct PPE) | 1 | ||
| Sub-Total | 2 | ||
| TASK 2: Component identification | |||
| Identified contactor (Award 1 mark for correct identification) | 1 | ||
| Identified motor (Award 1 mark for correct identification) | 1 | ||
| Identified auxiliary relay (Award 1 mark for correct identification) | 1 | ||
| Sub-Total | 3 | ||
| TASK 3: Use of tools and equipment | |||
| Used phase tester correctly (Award 1 mark for correct use) | 1 | ||
| Used digital multimeter correctly (Award 1 mark for correct use) | 1 | ||
| Used pliers correctly (Award 1 mark for correct use) | 1 | ||
| Used cable stripper correctly (Award 1 mark for correct use) | 1 | ||
| Sub-Total | 4 | ||
| TASK 4: Electrical testing and troubleshooting | |||
| Tested power supply in distribution board (Award 2 marks for correct testing) | 2 | ||
| Checked contactor terminals for complete connections (Award 2 marks for thorough checking) | 2 | ||
| Carried out continuity test on contactors and fuse box (Award 2 marks for correct continuity testing) | 2 | ||
| Identified faulty fuse box (Award 1 mark for correct identification) | 1 | ||
| Troubleshot motor connection (Award 1 mark for correct troubleshooting) | 1 | ||
| Troubleshot contactor (Award 2 marks for correct troubleshooting) | 2 | ||
| Replaced faulty fuse box correctly (Award 1 mark for correct replacement) | 1 | ||
| Corrected phase connection of motor (Award 2 marks for correct correction) | 2 | ||
| Terminated contactor correctly (Award 2 marks for correct termination) | 2 | ||
| Sub-Total | 15 | ||
| TASK 5: System operation and tests | |||
| Performed continuity tests (Award 2 marks for correct testing) | 2 | ||
| Performed polarity tests (Award 2 marks for correct testing) | 2 | ||
| Measured phase voltage correctly (Award 2 marks for correct measurement) | 2 | ||
| Performed visual inspection (Award 2 marks for thorough inspection) | 2 | ||
| Powered on the system (Award 2 marks for correct powering on) | 2 | ||
| Verified forward motor rotation (Award 2 marks for correct verification) | 2 | ||
| Verified reverse motor rotation (Award 2 marks for correct verification) | 2 | ||
| Powered off the system safely (Award 2 marks for correct powering off) | 2 | ||
| Sub-Total | 16 | ||
| TASK 6: Documentation and housekeeping | |||
| Wrote a brief breakdown maintenance report (Award 5 marks for clear and concise report) | 5 | ||
| Performed housekeeping (Award 2 marks for proper housekeeping) | 2 | ||
| Sub-Total | 7 | ||
| PRODUCT CHECKLIST | |||
| System tested and commissioned successfully with all components operating correctly (Award up to 10 marks for functional system and proper testing documentation) | 10 | ||
| Sub-Total | 10 | ||
| GRAND TOTAL | 57 | ||
Type: Individual
| Tools & Equipment | Materials |
|---|---|
| Digital Multimeter | Proximity sensor (inductive type) |
| Calibrated pressure gauge | Temperature sensor (PT100 RTD) |
| Calibrated temperature bath | Linear actuator 12V DC |
| Screwdriver set | Connecting cables 0.5 mm2 |
| Allen keys set | Personal Protective Equipment (PPEs) Safety boots and overall |
| S/N | Item | Quantity |
|---|---|---|
| 1 | Proximity sensor (inductive type) | 1 Pc per Candidate |
| 2 | Temperature sensor (PT100 RTD) | 1 Pc per Candidate |
| 3 | Linear actuator 12V DC | 1 Pc per Candidate |
| 4 | Digital Multimeter | 1 Pc per Candidate |
| 5 | Calibrated pressure gauge | 1 Pc per 5 Candidates |
| 6 | Calibrated temperature bath | 1 Pc per 5 Candidates |
| 7 | Screwdriver set | 1 Set per Candidate |
| 8 | Allen keys set | 1 Set per Candidate |
| 9 | Personal Protective Equipment (PPEs) Safety boots and overall | 1 Set per Candidate |
| 10 | Connecting cables 0.5 mm2 | 5 m per Candidate |
| Items to be Evaluated | Marks Available | Marks Obtained | Comments |
|---|---|---|---|
| TASK 1: Prepare and observe safety procedures | |||
| Worn appropriate PPE: safety boots and overall (Award 1 mark each for boots and overall) | 2 | ||
| Inspected sensors and actuator for physical damage (Award 2 marks for thorough inspection and reporting) | 2 | ||
| Checked availability and condition of calibration equipment (Award 2 marks for correct verification) | 2 | ||
| Connected sensors and actuator correctly to the test setup (Award 3 marks for correct and secure connections) | 3 | ||
| Sub-Total | 9 | ||
| TASK 2: Calibrate sensors | |||
| Calibrated proximity sensor using reference target at 5 mm distance (Award 4 marks for correct calibration and adjustment) | 4 | ||
| Calibrated PT100 sensor using temperature bath at 0°C and 100°C points (Award 5 marks for correct calibration and recording readings) | 5 | ||
| Verified sensor outputs with digital multimeter (Award 3 marks for accurate measurement and interpretation) | 3 | ||
| Sub-Total | 12 | ||
| TASK 3: Adjust and test actuator | |||
| Adjusted linear actuator stroke length to 50 mm using mechanical stops (Award 4 marks for precise stroke adjustment) | 4 | ||
| Tested actuator operation at 12 V DC supply (Award 3 marks for smooth and consistent movement) | 3 | ||
| Measured actuator stroke with a vernier caliper or ruler (Award 3 marks for measurement accuracy) | 3 | ||
| Sub-Total | 10 | ||
| TASK 4: Document and finalize calibration | |||
| Recorded calibration data and adjustments in the log sheet (Award 5 marks for complete and clear documentation) | 5 | ||
| Performed final system check for sensor and actuator functionality (Award 4 marks for successful system operation) | 4 | ||
| Conducted housekeeping: disconnected equipment and stored tools properly (Award 2 marks for proper housekeeping) | 2 | ||
| Sub-Total | 11 | ||
| PRODUCT CHECKLIST | |||
| Proximity sensor calibrated to detect at 5 mm ±0.5 mm (Award 4 marks for correct detection range) | 4 | ||
| PT100 temperature sensor calibrated with readings within ±1°C at 0°C and 100°C (Award 5 marks for accurate calibration) | 5 | ||
| Linear actuator stroke adjusted precisely to 50 mm ±1 mm (Award 5 marks for correct stroke length) | 5 | ||
| System operates correctly with sensors and actuator responding as expected (Award 6 marks for successful system function) | 6 | ||
| Sub-Total | 20 | ||
| GRAND TOTAL | 62 | ||