1. © 2007 Ideal Industries www.idealindustries.com 1 of 38 Meter Safety In the Workplace IDEAL’s Test and Measurement Meter Safety in the Workplace Sponsored by Bud Grant, ASM IDEAL Industries, Inc

2. © 2007 Ideal Industries www.idealindustries.com 2 of 38 Meter Safety In the Workplace Agenda Awareness of potential Measurement Hazards –OSHA and NFPA Explained –Arc Flash/Arc Blast –Who’s responsible for safety –Tools to keep you safe

3. © 2007 Ideal Industries www.idealindustries.com 3 of 38 Meter Safety In the Workplace Meters and Safety in the workplace OSHA (YOU Shall DO) 1926.416 29 CFR Ch. XVII (7-1-94 Edition) ( g) Use of Equipment. (1) Work on energized equipment. Only qualified persons may work on electrical circuit parts or equipment that have not been de-energized. Such persons shall be capable of working safely on energized circuits and shall be familiar with the proper use of special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools. NFPA 70E (How To) 130.2(C) Approach to Live Parts Operating at 50 volts or More: No qualified person shall approach or take any conductive object closer to exposed live parts operating at 50 volts or more than the Restricted Approach Boundary [minimum 3’ 6” for exposed fixed circuit part]… …unless… The qualified person is insulated or guarded from the live parts operating at 50 volts or more 70E 130.2(C)(1)

4. © 2007 Ideal Industries www.idealindustries.com 4 of 38 Meter Safety In the Workplace Meters and Safety in the workplace –Persons shall be trained in safety related work practices and procedures –A person should be able to identify and understand the relationship between the electrical hazards and possible energy. 110 Qualified Personal 110 6.(D)(1)( C) Proper Skills and Cognitive abilities to know the hazards and use proper Personal Protective Equipment. Article 110: (A) Training Shall apply to employees who face risk of electrical hazard

5. © 2007 Ideal Industries www.idealindustries.com 5 of 38 Meter Safety In the Workplace Why should we be Concerned? An electrician troubleshooting a live 480V motor control center receives serious second- and third-degree burns from an electric arc. The cause? –Meter was incorrectly switched on his multimeter to read resistance instead of voltage.

6. © 2007 Ideal Industries www.idealindustries.com 6 of 38 Meter Safety In the Workplace Why should we be Concerned? Two electricians are severely burned — one fatally — while testing for voltage in a motor starter. One held the multimeter while the other applied the meter's probes to energized terminals. One electrician's movement caused one test lead banana plug (energized from the circuit under test) to pull loose from the multimeter jack. –The plug made contact with the starter's grounded metal enclosure and initiated a high-energy arc.

7. © 2007 Ideal Industries www.idealindustries.com 7 of 38 Meter Safety In the Workplace Who is Responsible Personal Protection Equipment (PPE) –Arc Flash, insulating and shielding materials –Insulated tools –Test Equipment 110 6.(D) (1) (a) Persons shall be familiar with the proper use of special precautionary techniques

8. © 2007 Ideal Industries www.idealindustries.com 8 of 38 Meter Safety In the Workplace Who is responsible (E) Electrical safety program shall identify the procedure for working on, or near live parts >50 Volts (F) A procedure for evaluating hazard and risk associated with work on or near live parts operating above 50 volts, where an electrical hazard exists, before work can be started. The decision to work on energized circuits should be in accordance with guidelines as specified in Article 130.1 (A) 110.7 An employer shall implement an overall electrical safety program that directs the activities of employees when exposed to electrical hazards or risk.

9. © 2007 Ideal Industries www.idealindustries.com 9 of 38 Meter Safety In the Workplace Ratings for Test Equipment –IEC or UL 61010 Category ratings –Test equipment must be selected based on the intended use and expected voltage or current ratings. –Cost should not be a part of the equation. 110.9 (1)Test instrumentation, equipment and associated accessories must be rated for the circuits and equipment to which they will be connected.

10. © 2007 Ideal Industries www.idealindustries.com 10 of 38 Meter Safety In the Workplace Ratings for Test Equipment International Electro-technical Commission or IEC –IEC 61010 requires an instrument provide protection against “over-voltage impulse transients” - voltage spikes. –Electric Shock or burns –Mechanical hazards

11. © 2007 Ideal Industries www.idealindustries.com 11 of 38 Meter Safety In the Workplace Ratings for Test Equipment International Electro-technical Commission or IEC –IEC 61010 and is the basis for: ANSI/ISA-S82.01-94 (US) CAN C22.2 No. 1010.1-92 (CAN) EN61010-1:1993 (EUR) UL-61010B-1 61010B-1 incorporates features of the IEC 601010 standard, but this standard has improved safety benefits over the old UL384 and UL1244 standard

12. © 2007 Ideal Industries www.idealindustries.com 12 of 38 Meter Safety In the Workplace Ratings for Test Equipment High Voltage transients come from lightning, large inductive loads being switched on and off, or capacitive discharge –If a lighting strike was to hit your electrical service a certain amount of energy or impulse would travel and be dissipated by the electrical service. –The closer to the source of the impulse the Higher available fault current.

13. © 2007 Ideal Industries www.idealindustries.com 13 of 38 Meter Safety In the Workplace Impulse Fault –The closer to the source of the impulse the Higher available fault current. –If an instrument was to be hit by an impulse and a fault condition was to occur the Available energy “Fuels” the Fault. –Lets use the example of water or water pressure. –The larger the pipe the Greater the potential –The closer to the supply the Greater the potential Fireman with a 4 inch hose Faucet with ½ inch supply line

14. © 2007 Ideal Industries www.idealindustries.com 14 of 38 Meter Safety In the Workplace Ratings for Test Equipment Rating on input protection on Test instruments and Equipment are in order of potential available energy. The closer you are to the source the Higher the Category rating of the equipment IEC 61010 breaks energy rating down to four Categories: –CAT IV Origin of installation, –CAT III Distribution Level, –CAT II Local level, –CAT I Signal Level,

15. © 2007 Ideal Industries www.idealindustries.com 15 of 38 Meter Safety In the Workplace Ratings for Test Equipment CAT III-600V or CAT II-1000V? The greater the source impedance, the lower the Category: CAT III-600V: –6 kV impulse –2 Ohm test source CAT II-1000V: –6 kV impulse –12 Ohm test source A CAT III-600V 6kV test impulse has 6 times the current of a CAT II-1000V 6kV test impulse! Voltage rating by itself can be misleading. –CAT III-1000V (8kV transient) is safer than CAT III-600V (6kV transient) –But CAT III-600V is safer than CAT II-1000V What “Voltage” In the Rating Really means Remember Ohm’s Law Earlier

16. © 2007 Ideal Industries www.idealindustries.com 16 of 38 Meter Safety In the Workplace Certified Devices and Equipment Pay close attention to the safety rating on the equipment. –Never use equipment that is not properly rated [110.9 (1)] Look for tools that are Certificated by an independent lab, –UL, IEC, CSA. Never use accessories that are not recommended or rated for your tester or environment. IEC Cat ratings The New UL 61010B-1 standard incorporates features of the IEC 601010 standard. This standard has improved safety benefits over the old UL 1244 standard

17. © 2007 Ideal Industries www.idealindustries.com 17 of 38 Meter Safety In the Workplace Example, Visual Inspection –If an instrument or equipment show any signs of damage it most be removed from service. –Equipment may not be returned to service until it is properly repaired or replaced. 110.9 (3) Visually Inspect Equipment and all associated accessories for defects and damage

18. © 2007 Ideal Industries www.idealindustries.com 18 of 38 Meter Safety In the Workplace Example, Visual Inspection –Check for any contaminate on the test leads, tester case, holsters, and accessories. –Never use testers that have signs of cracked case, contaminants, loose or defective components. –Most defects are the result of normal wear around input connectors or terminals, function switches and controls. – Operational defects may not be so easily detected through a visual inspections. Low Batteries, Defective leads, fuses and etc. 110.9 (3) (cont)Visually Inspect Equipment and all associated accessories for defect and damage.

19. © 2007 Ideal Industries www.idealindustries.com 19 of 38 Meter Safety In the Workplace Example, Visually Inspection An easy test for testing leads is to use the meter’s ohms function. Short the leads and move the wire around the input connectors and lead grips. –If the meter reads 0.5 ohms leads may need to be replace. Some users are now using Fused lead. You may only need to change a fuse. Check for the following. –Insulation not damaged: melted or discolored, cut, cracked, or stretched –Connectors: no insulation pulled away from end connectors –Probe tips: arc burns, loose or broken Visually inspect Test Leads

20. © 2007 Ideal Industries www.idealindustries.com 20 of 38 Meter Safety In the Workplace Common Mistakes Made Make sure not to exceed the Max input of your meter. –Most common mistake is to measure voltage with the leads in the current inputs. –Current inputs are very low resistance. It appears as a short circuit to Voltage. –For current input protection most DMMs’ are Fused. –Look for high energy fusing. Current Protection Fuse Current input on a Digital multimeter normally has very low resistance And appears as a short circuit if voltage is measured Ideal 61-490 series give a probe error message and High audible warning if this mistake to done.

21. © 2007 Ideal Industries www.idealindustries.com 21 of 38 Meter Safety In the Workplace Common Mistakes Made Example: AC or DC voltage measurement with function switch in Ohms. Most Ideal meters are Overload Protected and the protected levels are listed in the operation manual. –User my get a false sense that the circuit is de-energized when in fact the circuit my be energized. Ideal 61-700 series will give you a Hi- V and audible warning if you make this Mistake Function Switch in wrong function for attempted measurement

22. © 2007 Ideal Industries www.idealindustries.com 22 of 38 Meter Safety In the Workplace Common Mistakes Made Example: 2,300 voltage measurement with an instrument rated for Low Voltage (600V AC/DC.) Overload Protected can not protect you from this Kind of mistake. Most Overload protected is rated based on instruments highest voltage measurement rating. There are Bold Electricians and Old electricians, but not many Bold-Old ones Using a meter in an area above its stated rating

23. © 2007 Ideal Industries www.idealindustries.com 23 of 38 Meter Safety In the Workplace Common Safety Hazards Select meter with the proper UL/IEC Category rating for the environment that user is going to be working in. High Voltage transients from lightning, large inductive loads being switched on and off, or capacitive discharge.

24. © 2007 Ideal Industries www.idealindustries.com 24 of 38 Meter Safety In the Workplace When should work begin –All possible sources are Identified –Isolate loads, open disconnect devices for each load –If possible, visually verify disconnect devices –Apply lockout/Tag-out devices in accordance to documented procedures or practices – Use properly rated Voltage Detection device to test Phase conductor or parts. Measure both phase to phase, and phase to ground. Use the three point measurement method Measure a know source first, the unknown, then back to the known 120.1 An electrical safe condition does not exist until the following conditions are met.

25. © 2007 Ideal Industries www.idealindustries.com 25 of 38 Meter Safety In the Workplace When should work begin –When there is a possibility of inducted or stored energy present ground the phase conductors When it could be possible that a de-energized circuit come in contact with a energized circuit use grounding connection devices rated for the possible available fault. Refer to 120.1 for an approved grounding connector.. –Induced (Ghost) Voltage conditions are cause by inductive ( or Capacitive) voltage into conductors in close proximity to other conductors. 120.1(cont.) An electrical safe condition does not exist until the following conditions are met.

26. © 2007 Ideal Industries www.idealindustries.com 26 of 38 Meter Safety In the Workplace Induced or Ghost Voltage Induced Voltage conditions can be tricky to detect. The input impedance of most Digital Multimeters are in the range of 10 Meg-Ohm This impedance is not sufficient to dissipate induced or what is sometimes call Ghost voltage. Low impedance testers or solenoid testers are very useful when testing were induced energy may be a problem.

27. © 2007 Ideal Industries www.idealindustries.com 27 of 38 Meter Safety In the Workplace Lockout/Tagout This is to ensure that when hazardous energy is removed that there is a controlled process that insures this state. That there is a method to verifie the absence of voltage using and approved voltage testing device. The employer shall provide training as required to ensure employees understand all aspects of the Lockout/Tag-out procedures. –120.2(E)(2) Employer must provide the necessary equipment to implement the requirements of lockout/tag out procedure. 120.2 Establishes the requirement for the implementation for Lockout/Tag-out procedures

28. © 2007 Ideal Industries www.idealindustries.com 28 of 38 Meter Safety In the Workplace Lockout/Tag-out –Many world class companies already have LO/TO programs in place –IDEAL conducts review Lock- out/Tag out seminars at distributors and at end user sites. –Training instruction material is also available if the end user wants adapt to current safety programs already in existence. 120.2(F) The employer must implement lockout/tag-out procedures for the company in accordance with and including elements and requirements as defined in article 120.

29. © 2007 Ideal Industries www.idealindustries.com 29 of 38 Meter Safety In the Workplace Testing –The testing device Who will use the testing device –The boundary of the safe zone established by the Lockout/tag-out –Requirements for testing a conductor before it is touched – Retesting if conditions change or job location has been left unattended. 120.2(F)(2)(f) Testing procedures shall establish the following.

30. © 2007 Ideal Industries www.idealindustries.com 30 of 38 Meter Safety In the Workplace *OSHA 1910.333 (a)(1) & NFPA 70 E 2-1.1.1 Qualified electrical workers shall not be asked to work on equipment that is “hot” or “live” except for two reasons : 1.De-energizing introduces additional or increased hazards a)Cutting ventilation to a hazardous location b)Interruption of life support equipment c)Deactivation of emergency alarms 2.It is infeasible due to equipment design or operational limitations a)Doing voltage testing for diagnostics or troubleshooting that can only be performed with the circuit energized When Can You Work Hot? NFPA-70E 130.1 Justification for Work

31. © 2007 Ideal Industries www.idealindustries.com 31 of 38 Meter Safety In the Workplace Approach Boundaries to Live parts –defined to four different approach boundaries. Limited Boundary Restricted Boundary Prohibited Boundary Flash protection Boundary –Approach boundaries are defended in Table 130.2 ( C) 130.2(A) Shock hazards analysis shall determine level personnel are exposed to hazards, and assess boundary Limits and requirements for PPE.

32. © 2007 Ideal Industries www.idealindustries.com 32 of 38 Meter Safety In the Workplace Approach Boundaries to Live parts Only Qualified Person shall perform testing work on or near live parts operating at >50 volts [110 6.(D) (1) (c )] Each person should be training to understand how to use specified test instruments and equipment 130.4 Test instrument and equipment use.

33. © 2007 Ideal Industries www.idealindustries.com 33 of 38 Meter Safety In the Workplace Not just Your Test Meters !! –Employee working in areas where there are electrical hazards shall be provided with, and shall use, protective equipment that is designed and constructed for the specific part of the body to be protected and for the work to be performed. 130.7 (A) Personal and Other Protective Equipment

34. © 2007 Ideal Industries www.idealindustries.com 34 of 38 Meter Safety In the Workplace OSHA Qualified Workers (g) Use of Equipment. (1) Work on energized equipment. Only qualified persons may work on electrical circuit parts or equipment that have not been de-energized under the procedures or paragraph (b) of this section. Such persons shall be capable of working safely on energized circuits and shall be familiar with the proper use of special precautionary techniques, personal protective equipment, insulating and shielding materials, and insulated tools. (OSHA Standard) § 1926.416 29 CFR Ch. XVII (7-1-94 Edition)

35. © 2007 Ideal Industries www.idealindustries.com 35 of 38 Meter Safety In the Workplace OSHA Protection Safeguards (a) Use of protective equipment.(1) Personal protective equipment.(i) Employees working in areas where there are potential electrical hazards shall be provided with, and shall use, electrical protective equipment that is appropriate for the specific parts of the body to be protected and for the work to be performed. § 1910.335 Safeguards for personal protection:

36. © 2007 Ideal Industries www.idealindustries.com 36 of 38 Meter Safety In the Workplace Interpreting OSHA Insulated hand tools (which conform to IEC 900 and ASTM F1505 standards) rated for the voltage involved would be considered insulation of the person from the energized part on which work is being performed. Generally, those tools which have a max. rated voltage of 1,000 volts for AC applications and 1,500 volts for DC applications would be suitable for work covered under the provisions of 29 CFR 1910 Subpart S. Official Interpretation From OSHA Officials:

37. © 2007 Ideal Industries www.idealindustries.com 37 of 38 Meter Safety In the Workplace Do you Test or Calibrate you Equipment? 250.1 Maintenance requirements for personal safety and protective equipment as listed must be maintained in accordance with the manufacturers recommendations or listing 250.2 Inspection and testing of protection equipment and protections tools –Visual inspection for damage or defects before use and intervals as required, but not to exceed 1 year. –Shall be verified by appropriate testing, at acceptable interval, to acceptable standards or practices, to insure proper operation.

38. © 2007 Ideal Industries www.idealindustries.com 38 of 38 Meter Safety In the Workplace Thank you You may want to refer to the Following NFPA 70E 2004, Handbook for electrical safety in the workplace. ANSI C62.41 - IEEE Recommended Practice on Surge Voltages IEC 60101 UL 601010B Case histories come from an IEEE paper entitled “Personnel Safety and Plant Reliability Considerations in the Selection and Use of Voltage Test Instruments,” ( IEEE Transactions on Industry Applications, Vol. 33, No. 2, March/April 1997),written by H. Landis Floyd II and Brian J. Nenninger. IDEAL Industries, Inc Test and Measurement Division 1 Becker Place Sycamore, Il 60178 (800) 435-0705