Electrical Measurement Safety

Electrical measurement safety
Understanding hidden hazards and new safety standards
2003 Fluke Corporation
Goals of this education program

Goals
Awareness of electrical measurement hazards Understand international safety specifications for DMMs and scopes Understand the four installation overvoltage categories Learn how to minimize and avoid electrical measurement hazards
Outline
What electrical power can do to a DMM Common safety hazards Meter safety inspection IEC Safety Standards Arc blast Meter and scope safety check list
Handheld test tool safety

How not to save time...
Last known earthly residence of automotive fuse used to replace original fuse
Test leads survived intact

This DMM had a hot date with 13.8 kV.
13.8 kV arced over to test probes.
Test leads destroyed
Insides were barbecued.

The wrong meter to use on a power circuit.
250V fuse didnt open in time
Probe tips burned off
Poor quality leads and probes led to injury.

The electrician suffered severe burn injuries on his hand and arm.
Fingerprints burned into probes

Typical work environment

Aftermath of an accident

If it melts metal, what does it do to people?
Common DMM / tester hazards

Arc from transients (lightning, load switching)
Protection: Independent certification to meet CAT III-1000 V or CAT IV 600 V
Voltage contact while in continuity or resistance

Protection: Overload protection in OHMs up to the meters volt rating
Measuring voltage with test leads in current jacks

Protection: High energy fuses rated to the meters voltage rating Use meters / testers without current jacks
Shock from accidental contact with live components

Protection: Test Leads double insulated, recessed / shrouded, finger guards, CAT III 1000 V. Replace when damaged
Using meter or tester above rated voltage

Protection: Good karma
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Common DMM safety hazards

Three common errors that are avoidable
Measuring voltage while test leads are in the current jacks: short-circuit!
Protection: Fluke meters use high energy fuses.
Contact with ac or dc power source while in Ohms mode.

Protection: Use a meter with Overload Protection. Functions are self-protected to the meters rated voltage.
Using meter above rated voltage, i.e., on medium voltage circuits.

Protection: Good karma
2003 Fluke Corporation Electrical measurement safety 11
Safety inspection
Test leads and probes
Check test lead resistance: Step 1: Insert leads in V/ and COM inputs. Step 2: Select , touch probe tips. Good leads are 0.1 - 0.3 .
How do you check a single test lead?
Visually check for:

CAT III-1000 V/CAT IV-600 V rating Double insulation Shrouded connectors, finger guards Insulation not melted, cut, cracked, etc. Connectors not damaged: no insulation pulled away from end connectors Probe tips: not loose or broken off
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Safety inspection
Checking meter fuses on most meters
Step 1: Plug test lead in V/ input. Select . Step 2: Insert probe tip into mA input. Read value. Step 3: Insert probe tip into A input. Read value. Is the fuse okay? What would an open fuse read?
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Safety Inspection
Overload protection on volts inputs
With leads in V/ and COM inputs:
Step 1: Select V and put probes in a live outlet. Will you damage the meter if you...
Step 2: Select mV Step 3: Select Step 4: Select A.
Overload protection is only to DMMs rated voltage.
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New IEC Safety Standards
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International Electrotechnical Commission

IEC 61010 is the new standard for low voltage test, measurement and control equipment.
IEC 61010 provides much improved protection against overvoltage impulse transients voltage spikes.
IEC 61010 is the basis for:
ANSI/ISA-S82.01-94 (US) CAN C22.2 No. 1010.1-92 (CAN) EN61010-1:1993 (EUR)
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IEC 61010 key concepts

Protection against overvoltage transients
CATEGORIES: CAT I to CAT IV
The greatest danger from transients is in the high categories, because they could trigger an arc blast.
IMPULSE TESTING: No failure allowed

Meters must be tested by being hit with a specified number of transients, with specified peak voltages.
INTERNAL SPACING: increased

Clearance (distance through the air) and Creepage (surface distance) are increased.
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Overvoltage category
The level and energy of voltage impulses is dependent on the location. The closer the location is to the power source, the higher the available fault current, the higher the category IEC 61010 defines four locations or categories:
CAT IV Origin of installation Utility level and any outside cable run CAT III Distribution wiring, including mains bus, feeders and branch circuits; permanently installed loads. CAT II Receptacle outlet circuit; plug-in loads. CAT I Protected electronic circuits
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Category locations
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Overvoltage category
Common sense ways to think of categories The higher the short circuit fault current available, the higher the category
High energy transients are much more dangerous, because they can trigger an arc blast
The greater the source impedance, the lower the category

Transients are dampened by system impedance as they travel from the point where they were generated.
TVSS (transient voltage surge suppression) devices are sized larger (more joules) at the panel than at the receptacle outlet.
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Determining the true voltage withstand rating

WITHIN each Category: There are designated working voltages (50, 150, 300, 600, 1000 V). A higher voltage has a higher transient withstand CAT IV example: CAT IV 600 V: 8 kV impulse CAT III example: CAT III 600 V: 6 kV impulse CAT III 1000 V: 8 kV impulse CAT II example: CAT II 600 V: 4 kV impulse CAT II 1000 V: 6 kV impulse
When is 600 V more than 1000 V?

CAT III-600 V or CAT II-1000 V? The greater the source impedance,the lower the Category: CAT IV-600 V:
8 kV impulse
CAT III-600 V:
6 kV impulse 2 ohm test source
CAT II-1000 V:
6 kV impulse 12 ohm test source A CAT III-600 V 6k V test impulse has 6 times the current of a CAT II-1000 V 6 kV test impulse!
First the CAT, then the voltage

Voltage rating by itself can be misleading.
CAT III-1000 V (8 kV transient) is safer than CAT III-600 V (6k V transient) But CAT III-600 V is safer than CAT II-1000 V
First know the category you are working in, then choose the appropriate voltage rating. If you ever measure power circuits, you should use a CAT III-600 V or CAT IV 600 V/CAT III-1000 V meter.
And CAT IV 600 V/CAT III-1000 V test leads and probes.
23
Look for CAT III or CAT IV markings
CAT III1000 V
CAT IV-600 V CAT III-1000 V
CAT III600 V
24
Levels of CAT III protection

CAT Transient with 2 Source 8000 V 6000 V 6000 V Fuse and Clearance Creepage overload (air) (surface) Rating 1000 V 1000 V 600 V 16.0 mm 11.5 mm 11.5 mm 16.0 mm 14.0 mm 11.5 mm
III-1000 V IV-600 V III-600 V II-1000 V II-600 V
25
Listed vs. designed to

IEC sets standards but does not test or inspect for compliance. A manufacturer can claim to design to a standard with no independent verification. To be UL-Listed, CSA or TUV-Certified , a manufacturer must employ the listing agency to TEST the products compliance with the standard. Look for the listing agencys emblem on the meter.
26
Designed to IEC 1010-1

But can the product pass testing...
Brand A
Markings Tested @ Creepage clearance CAT II 750 V CAT II 1000 V 3.7 mm Doesnt comply with 5.7 mm Input protection components opened
Brand B
CAT III 1000 V Input Cat III 1000 V 2.5 mm Doesnt comply with 16 mm Display window breakdown under high voltage
Brand C
D of C to IEC 1010-1 CAT III 1000 V 7.5 mm Doesnt comply with 16 mm Input protection components opened @ CAT II level
Transient tests
27
1 Flashover inside meter
2 Fault current in test leads
3 Arcing at the terminals

4 Arc blast
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Misuse of DMM in ammeter mode
29
Fuse protection on amps inputs
30
Whats the bottom line?

If you work on power circuits, you need a CAT III-600 V or CAT IV-600 V/ CAT III 1000 V meter. Look for the CAT rating and voltage rating marked near the input jacks.
CAT or voltage rating alone can be misleading
Look for independent certification. UL 3111
31

If you use a scope on power circuits, you need a CAT III-600 V scope and scope probes.
CAT III-600 V
Look for the CAT rating and voltage rating marked near the input jacks.
32

Safety must be built-in
An industrial grade meter devotes 10 % - 15 % of components exclusively to protection. Built-in protection against the most common safety hazards:
High voltage transients and danger of arc-over Voltage contact while in continuity or resistance mode High integrity components Voltage measurement while test leads are plugged into amps jacks High energy fuses Overload protection on all functions
1000V high energy fuses

33
What about my old meter?

Unless a meter was specifically designed to meet CAT III-600 V or higher, it is not safe to use on power circuits. Most meters produced before 1997 do not meet the standard.
Newer meters also have additional features and capabilities

Larger displays Back light 1000 Vac capability Capacitance Frequency Magnetic hangers Temperature 3X dc accuracy 2X ac accuracy
Original Fluke 70 Series
NOT RATED
Older Fluke 70 Series-III CAT II-600 V
New 170 Series
Min / Max Record Probe holders Battery door
UNDER RATED
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Meter safety checklist

Insist on these safety features:
Fused current inputs (high energy fuses). Overload protection on the ohms function. Test leads that have shrouded connectors and finger guards. Recessed input jacks. Meet the latest safety standards (CAT III-600 V or CAT IV 600 V/CAT III 1000 V) and are independently certified.
35
Meter safety checklist

Watch for:
Cracked or oily case Broken input jacks
No meter is safe when improperly used.

Use meters within their rating. Use meters designed for measurements on power circuits. Use replacement fuses approved by the manufacturer.
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Test lead safety checklist

Dont let test leads be a weak point
CAT III-1000 V or CAT IV 600 V/ CAT III 1000 V rating Double insulation Shrouded connectors Arc Flash Hazard consideration using specialized probes and PPE materials Finger guards Insulation not damaged: not melted, cut, cracked, stretched Connectors: no insulation pulled away from end connectors Probe tips: not loose or broken off (too short)
37
Safety first
Safe practices include but are not limited to:
Whenever possible, work on de-energized circuits. Follow proper lock-out/tag-out procedures. Use well maintained tools and appropriate safety gear
Safety glasses, insulated tools, insulating gloves, flash suits, insulating mats, etc.
Dont work alone. Practice safe measurement techniques.

Always connect the grounded lead first, hot second. Disconnect the hot lead first, grounded lead second.
Use the three-point test method.

Test known circuit, measure target circuit, then re-test known circuit.
Oscilloscope safety
Category ratings Select a scope and probes and clamps for the worst case category Voltage ratings Working voltage Transient voltage
Overvoltage category CAT I Working voltage (dc or ac rms to grnd) 600V Peak impulse transient (20 repetitions) 2500 V Test source (Ohm = V/A) 30 ohm source
CAT I
CAT II CAT II CAT III CAT III
1000V
600V 1000V 600V 1000V
4000 V
4000 V 6000 V 6000 V 8000 V
30 ohm source
12 ohm source 12 ohm source 2 ohm source 2 ohm source
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Oscilloscope safety
Line powered bench scopes
Use a differential or isolation probe to separate the earth ground connection of the scope from high energy circuits that are also referenced to earth ground. Isolate bench scope grounds only in conjunction with differential/isolation probes.
+ Differential Input 50 BNC Output
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Oscilloscope safety
DC VOLTAGE
TO MOTOR
DC VOLTAGE
Typical use of a differential probe
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Oscilloscope safety
Battery powered scopes Have inherent ground isolation for superior common mode noise rejection Some come standard with CAT III 600 volt probes for measurements in high energy circuits
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Oscilloscope safety
Probes
Beware of bench scope probes - they are usually CAT I - 500 volts Dont use CAT I or II divider probes on CAT III circuits Dont use probes with exposed metal parts Dont use probes without specified ratings Read the manual for safe probe connections - they may vary greatly between instruments
43
Oscilloscope safety
Safe practices
De-energize circuits Use protective gear Do not exceed instrument voltage and category ratings Use dc coupling - ac coupling may not reveal dangerous voltages Use 3-point test method
Test known live circuit Test target circuit Test known live circuit again
Avoid holding or touching the scope if possible
44
Oscilloscope safety
Current clamps
Clamps have category and working voltage ratings Do not exceed them
CAT III circuits - Make sure you use Cat III leads AND scope AND current clamp
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If you use a scope on power circuits, you need a CAT III-600 V scope and scope probes. CAT II scopes and probes are mainly for loads that plug into a receptacle outlet.
CAT III-600 V
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CAT IV
Equipment of overvoltage category IV is for use at the origin of the installation (utility service). Outside and service entrance Service drop from pole to building
Run between meter and panel

Overhead line to detached building Underground line to well pump22
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CAT III
Premises wiring: mainscircuits, i.e., bus and feeders and distribution panels Permanently installed loads: motors, lighting systems, drives, load centers Typically separated from utility service by at least a single level of transformer isolation Does not include receptacle plug-in loads, except in the case of heavy appliance outlets with short connections to service entrance
CAT II
Loads that plug in at receptacle outlet
Examples of such equipment are appliances, portable tools and other household and similar loads All outlets at more than 10 m (30 ft) from Category III All outlets at more than 20 m (60 ft) from Category IV
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CAT I
Equipment in which measures are taken to limit transient overvoltages to an appropriately low level
Examples are protected electronic circuits. A copier that has an internal step-up transformer and 1000 Vdc is still a CAT I-1000 V machine, because the current levels are so low
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Electrical Measurement Safety

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Electrical measurement safety

Understanding hidden hazards and new safety standards

2003 Fluke Corporation