Safety Bulletin

Additional, Urgent Information as of August 2010

Subject: OSHA Is Stepping Up Enforcement of the NFPA 70E2009 Voluntary Standard for Electrical Safety in the WorkplaceAre You Ready? Introduction
This bulletin describes the key issues that mechanical service companies face with regard to NFPA 70E. Several of these issues are new. It also highlights some of the major differences between NFPA 70E2004 and NFPA 70E2009.

Provided as a service of MCAAs Safety Excellence Initiative

Urgent Points
OSHA is stepping up enforcement on what it perceives to be electrical safety hazards. The agency is emphasizing electrical safety through intensified enforcement. To understand your obligations as an employer be sure to read all of the bullets under the general heading below. In the past, 4 to 8 calorie flame resistant (FR) pants and shirt or coveralls were deemed to be acceptable for work on HVAC units pushing 480 volts or less. However, 8 calorie FR pants and shirt or coveralls is now the minimum recommended standard. There is a major difference between Hazard Risk Category 2 and Hazard/Risk Category 2*. The asterisk denotes the need for additional protection in the form of an 8 calorie (minimum) FR balaclava under a Class E hardhat and 8 calorie arc-flash face shield, or an arc-rated arc flash suit hood. Work on most HVAC units pushing 480 volts or less places our workers in Hazard/Risk Category 2*. The FR balaclava is preferred by most HVAC technicians because it is lighter, cooler, and much less cumbersome than an arc flash suit hood. The NFPA 70E default tables place mechanical service technicians in Hazard/Risk Category 2* when performing work on HVAC units pushing 480 volts or less. However, you may, on rare occasions, come across units pushing 480 volts or less that are labeled Hazard/Risk Category 3. Hazard/Risk Category 3 requires personal protective equipment and safe work practices that are more protective than those required for Hazard/Risk Category 2*. If your workers are required to work on units labeled Hazard/Risk Category 3, be sure they have the proper training and personal protective equipment needed to perform the work safely.

For additional information about this topic or to learn more about MCAAs Safety Excellence Initiative, contact Pete Chaney at 800-556-3653 or pchaney@mcaa.org.

General
NFPA is the National Fire Protection Association. The organization develops and produces codes and standards, including the National Electrical Codes. NFPA 70 refers to the National Electrical Codes. NFPA 70E is a national Standard for Electrical Safety in the Workplace. The standard is revised every three to five years. The most current version is NFPA 70E 2009. NFPA 70E is a voluntary standard, which was developed to address electrical workplace hazards involving industrial and power generated switch gear operations. Little consideration was given to the mechanical service industry during development of the standard. However, mechanical service companies have been held liable for failing to protect their workers from arc flash and electrical shock hazards by using safe work practices such as those described in NFPA 70E. Employers could become defendants in lawsuits where plaintiff attorneys wave the most current NFPA 70E standard in front of the juries to make the case that the defendant should have been in compliance with the industrys most applicable consensus standard, regardless of whether it is voluntary. In the past OSHA issued general duty clause citations to employers who it perceived werent properly protecting their workers from arc flash hazards. The agency still issues general duty clause citations. However, OSHA has changed its approach to enforcement and is more likely to issue other types of citations.

Most Common OSHA Citations Related to Electrical Safety (Presently)

% of Citations 60 30 Reason for Citation Lack of Proper Arc Flash Personal Protective Equipment 29CFR 1910.132(d)(1) & 29CFR 1910.335(a)(1) Lack of Qualified-Level Arc Flash Training 29CFR 1910.332 Subpart S & 29CFR 1910.132(f)(1-4) & Section 5(a)(1) of the Occupational Safety and Health Act of 1970 (General Duty Clause) Miscellaneous citations such as failure to have gloves dielectrically tested every 6 months, failure to establish barricades around open electrical panels, etc. Failure to establish a written electrical safety program is cited almost every time. If you dont have a written program, visit www.mcaa.org/private/safety or www.mcaa.org/store and download the Model NFPA 70E 2009 Electrical Safety Program for Service, which was revised last year to reflect changes to the NFPA 70E code. Be sure to tailor the model program to meet your companys specific needs. The minimum recommended components 2

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of an electrical safety program based on NFPA 70E 2009 follow the Twenty Key Changes Side By Side Comparison chart in this bulletin.

Included in this bulletin are comparisons of 20 changes between NFPA 70E 2004 and
NFPA 70E 2009 that MCAA/MSCA believes are key to mechanical service worker safety when working on HVAC units/equipment pushing 480 volts or less.

Twenty key changes: a side-by-side comparison

The following chart provides a side-by-side comparison of 20 changes to NFPA 70E that occurred between the 2004 and 2009 versions. The changes highlighted in this bulletin do not encompass all of the changes made to NFPA 70E 2009. However, MCAA/MSCA believes these changes are the ones most likely to affect mechanical service work on units pushing 480 volts or less. If you would like a copy of NFPA 70E 2009, contact NFPA at 617-770-3000 or go to www.nfpa.org.

NFPA 70E 2009

1. Host Employers Must Now Communicate Hazards to Contract Employers.
110.5 Relationships with Contractors (Outside Service Personnel, etc.) (A) Host Employer Responsibilities: (1) The host employer shall inform contract employers of: Known hazards that are covered by this standard that are related to the contract employer or its employees; and Information about the employers installation that the contract employer needs to make the required assessments. (2) The host employer shall report observed contract-employer-related violations of this standard to the contract employer.

NFPA 70E 2004

110.4 (equates to 110.5 in the 2009 version) Multiemployer Relationship (A) Safe Work Practices: On multi-employer worksites (in all industry sectors), more than one employer may be responsible for hazardous conditions that violate safe work practices.

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NFPA 70E 2009

2. Contract Employers Must Now Communicate the Hazards Learned from Host Employers to Their Own Employees.
110.5 Relationships with Contractors (Outside Service Personnel, etc.) (B) Contract Employer Responsibilities: (1) The contract employer shall ensure that each of his or her employees is instructed in the hazards communicated to the contract employer by the host employer. This instruction is in addition to the basic training required by this standard. (2) The contract employer shall ensure that each of his or her employees follows the work practices required by this standard and safety-related work rules required by the host employer. (3) The contract employer shall advise the host employer of: Any unique hazards presented by the contract employers work, Any unanticipated hazards found during the contract employers work that the host employer did not mention, and

NFPA 70E 2004

110.4 (equates to 110.5 in the 2009 version) Multiemployer Relationship (B) Outside Personnel (Contractors, etc.): Whenever outside servicing personnel are to be engaged in activities covered by the scope and application of this standard, the on-site employer and the outside employer(s) shall inform each other of existing hazards, personal protective equipment/clothing requirements, safe work practice procedures, and emergency/ evacuation procedures applicable to the work to be performed. This coordination shall include a meeting and documentation.

The measures the contractor took to

correct any violations reported by the host employer to prevent such violations from recurring in the future.

3. CPR Training Must Now Be Certified by the Employer Annually.

110.6 Training Requirements (C) Emergency Procedures: Employees exposed to shock hazards shall be trained in methods of release of victims from contact with exposed energized electrical conductors or circuit parts. Employees shall be regularly instructed in methods of first aid and emergency procedures, such as approved methods of resuscitation, if their duties warrant such training. Training of employees in approved methods of resuscitation, including cardiopulmonary resuscitation, shall be certified by the employer annually. 110.6 Training Requirements (C) Emergency Procedures: Employees working on or near exposed energized electrical conductors or circuit parts shall be trained in methods of release of victims from contact with exposed energized conductors or circuit parts. Employees shall be regularly instructed in methods of first aid and emergency procedures, such as approved methods of resuscitation, if their duties warrant such training.

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NFPA 70E 2009

4. Employees Must Now Receive Special Training On Proper Selection and Use of Voltage Detectors.
110.6 Training Requirements (D) Employee Training (1) Qualified Person (e): Employees shall be trained to select an appropriate voltage detector and shall demonstrate how to use a device to verify the absence of voltage, including interpreting indications provided by the device. The training shall include information that enables the employee to understand all limitations of each specific voltage detector that may be used.

NFPA 70E 2004

110.6 Training Requirements (D) Employee Training (1) [(e) is non-existent in the 2004 version of NFPA 70E]

5. Employees Must Now Receive Retraining Based on Three Specified Conditions.

110.6 Training Requirements (D) Employee 110.6 Training Requirements (D) Employee Training (3) Retraining (a) (b) and (c): An employee Training [(3) Retraining is non-existent in the 2004 shall receive additional training (or retraining) Version of NFPA 70E] under any of the following conditions: (a) If the supervision or annual inspections indicate that the employee is not complying with the safetyrelated work practices; (b) If new technology, new types of equipment, or changes in procedures necessitate the use of safety-related work practices that are different from those that the employee would normally use; (c) If he or she must employ safety-related work practices that are not normally used during his or her regular job duties.

6. Employers Must Now Document Their Electrical Safety Programs.

110.7 Electrical Safety Program (A) General: The employer shall implement and document an overall electrical safety program that directs activity appropriate for the voltage, energy level, and circuit conditions. 110.7 Electrical Safety Program (A) General: The employer shall implement an overall electrical safety program that directs activity appropriate for the voltage, energy level, and circuit conditions.

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NFPA 70E 2009

7. Employers Must Now Identify in Their Electrical Safety Programs the Hazard/Risk Process that is to be Used by Their Employees to Evaluate Tasks Before Starting Work.
110.7 Electrical Safety Program (F) Hazard/Risk Evaluation Procedure: An electrical safety program shall identify a hazard/risk evaluation procedure to be used before work is started within the Limited Approach Boundary of energized electrical conductors and circuit parts operating at 50 volts or more or where an electrical hazard exists. The procedure shall identify the hazard/risk process that shall be used by employees to evaluate tasks before work is started.

NFPA 70E 2004

110.7 Electrical Safety Program (F) Hazard Risk Evaluation Procedure: An electrical safety program shall identify a hazard/risk evaluation procedure to be used before work is started on or near live parts operating at 50 volts or more or where an electrical hazard exists.

8. Affected Employers Must Now Audit Their Electrical Safety Programs.

110.7 Electrical Safety Program (H) Electrical Safety 110.7 Electrical Safety Program [(H) Electrical Auditing: An electrical safety program shall be Safety Auditing is non-existent in the 2004 version audited to help ensure that the principles and of NFPA 70E] procedures of the electrical safety program are being followed. The frequency of audit shall be determined by the employer, based on the complexity of the procedures and the type of work being covered. Where the audit determines that the principles and procedures of the electrical safety program are not being followed, appropriate revisions shall be made.

9. Affected Employees Must Now Implement a New Procedure for Testing Voltage on Conductors and Circuit Parts Operating at 50 Volts or More.
110.9 Use of Equipment (A) Test Instruments and 110.9 Use of Equipment (A) [(4) Operation Equipment (4) Operation Verification: When test Verification is non-existent in the 2004 version of instruments are used for testing for the absence of NFPA 70E] voltage on conductors or circuit parts operating at 50 volts or more, the operation of the test instrument shall be verified before and after an absence of voltage test is performed. [First, test the meter on a known, live source. Second, test the conductor or circuit part for the presence of voltage. Third, test the meter again on the known live source before beginning work on the conductor or circuit part.]

NFPA 70E 2009

10. The Authorized Employee in Charge of Complex Lockout/Tagout Procedures Must Now Attach a Personal Lockout or Tagout Device to the Group Lockout System.
120.2 Deenergized Electrical Conductors or Circuit Parts that Have Lockout/Tagout Devices Applied (D) Hazardous Electrical Energy Control Procedure (3) Complex Lockout/Tagout Procedure. (b) All complex lockout/tagout procedures shall require a written plan of execution that identifies the person in charge. (c) The complex lockout/tagout procedure shall vest primary responsibility in an authorized employee for a set number of employees working under the protection of a group lockout or tagout device (such as an operation lock). The person in charge shall be held accountable for safe execution of the complex lockout/tagout. (d) Each authorized employee shall affix a personal lockout or tagout device to the group lockout device, group lockbox or comparable mechanism when he or she begins work, and shall remove those devices when he or she stops working on the machine or equipment being serviced or maintained.

NFPA 70E 2004

120.2 Working On or Near Deenergized Electrical Conductors or Circuit Parts That Have Lockout/ Tagout Devices Applied (D) Hazardous Electrical Energy Control Procedures (3) Complex Lockout/ Tagout Procedure: (b) A person shall be in charge of a complex lockout/tagout procedure. Such person shall be a qualified individual who is specifically appointed with overall responsibility to ensure that all energy sources are under lockout/tagout and to account for all persons working on the job/task. (c) The complex lockout/ tagout procedure shall identify the person in charge. In this (these) instances(s), the person in charge shall be permitted to install locks/tags, or direct their installation, on behalf of other employees. The person in charge shall be held accountable for safe execution of the complex lockout/tagout. The complex lockout/tagout procedure shall address all the concerns of employees who might be exposed. All complex lockout/tagout procedures shall require a written plan of execution that identifies the person in charge. All complex lockout/tagout plans shall identify the method to account for all persons who might be exposed to electrical hazards in the course of the lockout/tagout.

11. Energized Electrical Conductors and Circuit Parts Operating at Less than 50 Volts No Longer Have to be De-energized when Specified Criteria are Met.
130.1 Justification for Work (A) General (3) Less 130.1 Justification for Work [(A) General is nonThan 50 Volts: Energized electrical conductors and existent in the 2004 version of NFPA 70E] circuit parts that operate at less than 50 volts to ground shall not be required to be de-energized where the capacity of the source and any overcurrent protection between the energy source and the worker are considered and it is determined that there will be no increased exposure to electrical burns or to explosion due to electric arcs.

NFPA 70E 2009

12. Employers Must Now Review Arc Flash Hazard Analyses More Frequently.
130.3 Arc Flash Hazard Analysis: An arc flash hazard analysis shall determine the Arc Flash Protection Boundary and the personal protective equipment that people within the Arc Flash Protection Boundary shall use. The arc flash hazard analysis shall be updated when a major modification or renovation takes place. It shall be reviewed periodically, not to exceed five years, to account for changes in the electrical distribution system that could affect the results of the arc flash hazard analysis.

NFPA 70E 2004

130.3 Flash Hazard Analysis: A flash hazard analysis shall be done in order to protect personnel from the possibility of being injured by an arc flash. The analysis shall determine the Flash Protection Boundary and the personal protective equipment that people within the Flash Protection Boundary shall use.

13. An Arc Flash Hazard Analysis is no Longer Required Under Specified Circumstances When the Circuit is Rated at 240 Volts or Less.
130.3 Exception 1: An arc flash hazard analysis is no longer required when the circuit is rated 240 volts or less, the circuit is supplied by one transformer, and the transformer supplying the circuit is rated less than 125 kVA. 130.3: [Exceptions are non-existent in the 2004 version of NFPA 70E]

14. There are Now Reductions to the Product of Clearing Times and Available Bolted Fault Current Allowed When Determining Arc Flash Protection Boundary Requirements.
130.3 (A) Arc Flash Protection Boundary (1): Voltage Levels Between 50 Volts and 600 Volts: In those cases where detailed arc flash hazard analysis calculations are not performed for systems that are between 50 volts and 600 volts, the Arc Flash Protection Boundary must be 4.0 ft, based on the product of clearing time of 2 cycles (0.033 sec) and the available bolted fault current of 50 kA or any combination not exceeding 100 kA cycles (1667 ampere seconds). When the product of clearing times and bolted fault current exceeds 100 kA cycles, the Arc Flash Protection Boundary must be calculated. 130.3 (A) Flash Protection Boundary: For systems that are 600 volts or less, the Flash Protection Boundary must be 4.0 ft. based on the product of clearing times of 6 cycles (0.1 seconds) and the available bolted fault current of 50 kA or any combination not exceeding 300 kA cycles (5000 ampere seconds). For clearing times and bolted fault currents other than 300 kA cycles or under engineering supervision, the Flash Protection Boundary must alternatively be permitted to be calculated in accordance with the general formula.

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NFPA 70E 2009

15. Equipment Must Now Have Specified Labels.
130.3 Flash Hazard Analysis (C) Equipment Labeling: Equipment shall be field marked with a label containing the available incident energy or required level of PPE.

NFPA 70E 2004

130.3 Flash Hazard Analysis: [(C) is non-existent in the 2004 version of NFPA 70E]

16. Hazard/Risk Category Classifications Have Now Changed for Non-contact Inspections Outside the Restricted Approach Boundary.
Table 130.7(C)(9) General Notes (f): For equipment protected by upstream current limiting fuses with arcing fault current in their current limiting range (1/2 cycle fault clearing time or less), the hazard/risk category required may be reduced by one number. Table 130.7(C)(9): [Note (f) is non-existent in the 2004 version of NFPA 70E]

17. Denim Cotton Blue Jeans Are No Longer Permitted When Flame Resistant (FR) Pants are Required.
Table 130.7(C)(10) Protective Clothing and Personal Protective Equipment (PPE): FR Clothing Minimum Arc Rating of 4 (Note 1) See Table 130.7(C)(11). Arc rating for a garment or system of garments is expressed in cal/cm2. Arc-rated pants (Note 3) The FR shirt and pants used for Hazard/Risk Category 1 must have a minimum arc rating of 4. Table 130.7(C)(10) Protective Clothing Personal Protective Equipment (PPE) Matrix: Non-melting or Untreated Natural Fiber Hazard Risk Category 1 c. Pants (long) (Note 4) Regular Weight (minimum 12 oz/yd2 fabric weight) untreated, denim cotton blue jeans are acceptable in lieu of FR pants. The FR pants used for Hazard/Risk Category 1 must have a minimum arc rating of 4.

18. A FR Balaclava Must Now Be Used with Arc-rated Face Shields for Hazard/Risk Category 2*.
Table 130.7(C)(10) Protective Clothing and Personal Protective Equipment (PPE): FR Clothing Hazard Risk Category 2* FR Clothing, Minimum Arc Rating of 8 (Note 1) See Table 130.7(C)(11). Arc rating for a garment or system of garments is expressed in cal/cm2. Arc-rated flash suit hood (Note 10) Alternate is to use a face shield with a minimum arc rating of 8 and a balaclava (sock hood) with a minimum arc rating of 8 and which covers the face, head and neck except for the eye and nose areas. Table 130.7(C)(10) Protective Clothing Personal Protective Equipment (PPE) Matrix: FR Protective Equipment Hazard Risk Category 2* e. Face and head area protection 1. Arc-rated face shield, or flash suit hood (Note 8) A face shield with a minimum arc rating of 8, with wrap-around guarding to protect not only the face, but also the forehead, ears, and neck (or, alternatively, a flash suit hood), is required.

NFPA 70E 2009

19. Ear Plugs Are Now Required for Hearing Protection in All Hazard/Risk Categories.
Table 130.7(C)(10) Protective Clothing and Personal Protective Equipment (PPE): Hearing Protection Hazard Risk Categories 1, 2, 3 and 4 Hearing Protection (ear canal inserts)

NFPA 70E 2004

Table 130.7(C)(10) Protective Clothing Personal Protective Equipment (PPE) Matrix: Hearing Protection Hazard Risk Categories 2, 3 & 4 Hearing Protection (ear canal inserts)

20. Under-layers of Non-FR Natural Fiber Clothing Such as Cotton No Longer Count Toward the Total Required FR Protection.
Table 130.7(C)(11) Protective Clothing Characteristics: Clothing Description Hazard Risk Category 1 Arc-rated FR shirt and FR pants or FR coverall Hazard Risk Category 2 Arc-rated FR shirt and pants, or coverall, and arc flash suit selected so that the system arc rating meets the required minimum. Table 130.7(C)(11) Protective Clothing Characteristics: Layering Hazard Risk Category 1 FR shirt and FR pants or FR coverall (Typical number of clothing layers 1) Hazard Risk Category 2 Cotton Underwear Conventional short sleeve, and brief/shorts, plus FR shirt and FR pants (Typical number of clothing layers 1 or 2)

NFPA 70E 2009 Electrical Safety Program Components for Service The following are minimum recommended components of an electrical safety program for mechanical service work on units pushing 480 volts or less. Items that are new to the 2009 version of the standard are bolded, italicized, and underlined. Affected Employers must implement and carefully document an overall electrical safety program that directs activity appropriate for the voltage, energy level, and circuit conditions. Minimum Program Principles: Electrical safety inspection and evaluation of each HVAC unit. Maintenance of each units electrical insulation and the integrity of each units enclosure. Pre-planning of every job. Documentation of any first-time procedures. De-energizing of each unit immediately after troubleshooting is completed and before repair work/maintenance begins. Anticipation of unexpected events. Identification and minimization of potential hazards. The hazard/risk process that is to be used by employees to evaluate tasks before starting work.

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 Technician protection from shock, burn, blast, and other applicable hazards due to the work environment. Use of tools that are appropriate for the job. Assessment of the abilities of anyone who could be exposed to potential electrical hazards from repair or maintenance work on the HVAC units. Occasional audits of all of these principles. Protection of unqualified persons. Electrical safety program controls must be established to measure and monitor the electrical safety program. Minimum Program Controls: Workers and their supervisors are responsible for ensuring that guards or protective measures are satisfactory for the conditions. Affected workers must consider every electrical conductor or circuit part to be energized until it is shut off, locked out, and tested dead. All affected workers must consider the actual process of de-energizing an electrical conductor or circuit part a potentially hazardous task. Affected workers must not make bare hand contact with exposed, energized electrical conductors or circuit parts. All affected workers must receive electrical safety training in accordance with the program. All affected workers must receive a copy of this program. All affected workers must obtain answers to any questions they have about the program, before they begin work. All affected workers must consistently implement this program.

All affected workers must use the procedures described in the program to identify

potential electrical hazards associated with their work, and control or eliminate them.

Only troubleshooting procedures may be used on or near exposed, energized electrical conductors and circuit parts unless the unit being serviced has a built-in interlocking disconnect. Where work is being performed on units with built-in interlocking disconnects, workers must implement the safe work practices, including use of the personal protective equipment, required for work on all energized equipment with exposed live parts. All affected workers must be alert when working on or near the equipment.

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 Workers must not perform work on the equipment while they are impaired by illness, fatigue, prescription drugs, non-prescription drugs, illegal drugs, alcohol, or other impairments. Workers must never reach blindly into areas that could contain exposed live parts. Workers must ensure that their work areas are properly illuminated so that their work can be performed safely. Workers must not wear conductive articles of jewelry and/or clothing. Any conductive objects being carried by a worker must be handled in a manner that prevents accidental contact with exposed energized parts. Where a worker must work in a confined or enclosed work space he or she must use protective barriers or insulating materials to prevent contact with exposed energized parts. Housekeeping must not be performed where there is a possibility of contact with exposed energized parts, unless barriers or insulating equipment is used to prevent contact. All affected workers must identify and use the precautions that are appropriate for the work environment. Employers must provide electrical safety training for all affected workers Minimum Electrical Safety Training Topics: The contents of the electrical safety program with emphasis on the safe work practices, procedures and personal protective equipment requirements The companys established Qualified Person - Approach Boundary for protection from electrical shock and arc flash hazards Identification of electrical hazards associated with work on units pushing 480 volts or less The decision making process necessary to determine: o the degree of the hazards; o the extent of the hazards; and o pre-planning practices needed to perform the job safely. Proper selection and use of voltage detectors Techniques necessary to distinguish energized parts from other parts of the units Techniques necessary to determine the nominal voltage of exposed energized unit parts Methods of protection from the electrical hazards Skills necessary to select properly rated test equipment and tools 12

 Selection, inspection and maintenance of personal protective equipment including pre-use leak testing, and bi-annual dielectric testing of protective rubber gloves Additional training or retraining must occur: If the supervisor or annual inspections indicate that the employee is not complying with the safety-related work practices. If new technology, new types of equipment, or changes in procedures necessitate the use of safety-related work practices that are different from those that the employee would normally use. Each time there is a change in the process and when an audit or incident investigation determines that additional training is necessary. If the employee must employ safety-related work practices that are not normally used during his or her regular job duties. When an audit or incident investigation determines that additional training is necessary. Employers must provide the appropriate personal protective equipment (PPE). PPE Required for Work on Units Pushing 480 Volts or Less Voltage Clothing Gloves
480 Volts or Less Flame Resistant (FR) Long Sleeve Shirt and Pants or Coverall (8 Calorie FR Protection) Class 00 Rubber Gloves with Leather Protector Gloves Over the Rubber Gloves

Other PPE
Safety Glasses, Class E Hard Hat with 8 Calorie ATPV Face Shield, 8 Calorie FR Balaclava, Ear Plugs

Protective Clothing Workers must wear long sleeve shirts and pants or a coverall made of Flame Resistant (FR) material. The protective equipment must have an Arc Thermal Protective Value (ATPV) of 8 cal/cm2. The ATPV will be displayed outside the clothing or on a tag inside. Eye Protection Standard safety glasses must be worn at all times by technicians while performing any mechanical service work. The safety glasses must be worn at all times, even while using an arc-rated face shield. Head and Face Protection When working on units pushing 480 volts or less, workers must wear a Class E hard hat with an attached arc-rated face shield and an FR rated balaclava. The face shield and the balaclava must each have a minimum Arc Thermal Protective Value (ATPV) of 8 cal/cm2. Hearing Protection When working on units pushing 480 volts or less, workers must wear ear canal inserts (ear plugs). Hand Protection When working on units pushing 480 volts or less, workers must wear Class 00 Rubber gloves and leather protector gloves over the rubber gloves. Rubber gloves must be 13

dielectrically tested at a certified testing laboratory at least every six months. Technicians must field test their gloves before each use by trapping air inside each glove and looking/feeling for leaks. Gloves with leaks or any signs of scratches or other damage will be destroyed and discarded immediately. Employers must establish electrical safety program procedures. Minimum Electrical Safety Program Procedures: Supervisors must: Ensure that all of their workers have received the proper electrical safety training as described in this program before they are permitted to begin work. Ensure that their workers receive a copy of the program and understand the programs principles, controls, and specific electrical safety training requirements. Assess their workers abilities by testing them on the knowledge they need to protect themselves from electrical hazards. Conduct audits to ensure that all of the electrical safety program principles are appropriate, and being followed by the affected workers. The frequency of the audits is to be based by the employer on the complexity of the procedures and the type of work being covered. Affected workers must: Carefully plan each job well before the start-up time. Ensure that all of the proper tools, equipment, and permits are present. Never approach closer than four feet from an energized unit with exposed live parts without following the appropriate safe work practices and personal protective equipment requirements. The four-foot approach and protection boundary is the greater of the two boundaries established for qualified persons for shock and arc flash protection. The four foot boundary applies to any conductive objects that are being carried by workers.

Before opening the access door or removing the panel to any energized equipment, labeled Hazard/Risk Category 3 or higher, and/or if it is pushing more than 480 volts, this program does not apply. Before you proceed, obtain and follow an
electrical safety program established for units pushing the higher voltage of the unit you will be servicing. Before opening the access door or removing the panel to the energized unit, put on the following personal protective equipment. o 8-calorie flame resistant (FR) long sleeve shirt and pants or coveralls; 14 inspect/evaluate it to determine the voltage capacity. Ensure that all visible parts appear to be in good condition. Look for a Hazard/Risk Category Label. If the unit is

o Ear plugs; o Safety glasses; o Class E hardhat; o 8-calorie arc-rated face shield; o 8-calorie flame resistant (FR) balaclava; o Class 00 rubber gloves; and o Leather protective gloves (over the rubber gloves). Only use properly rated test instruments (multimeters) and ammeters to test electrical circuits. Visually inspect all testing equipment including the leads, cables, power cords, probes, and connectors each time before you use them. Verify the operation of the test instrument before and after an absence of voltage test is performed. Attach a Danger Do Not Use sign to equipment that appears damaged and take it out of service immediately. Use all testing instruments in conformance with manufacturers recommendations. Only use test instruments that has been provided by the company. Use only properly rated insulated tools to conduct troubleshooting. Complete troubleshooting. Stand to one side of the external service disconnect when shutting off the power. Shut off the power and lockout the disconnect that supplies the unit. Follow the companys lockout procedures as described in the program. (This step does not apply to units with built-in interlocking disconnects.) Check the test instrument on a known live source. Test the unit to ensure that the power has been shut off. Go back and recheck the test instrument on a known live source. If there are any inconsistencies or discrepancies, replace the test instrument and repeat the process to ensure that the unit has been de-energized. Discharge any stored energy such as the current in the capacitors. Once the unit is tested dead you may remove gloves, hard hat, arc-rated face shield, arc-rated balaclava, ear plugs and flame resistant (FR) clothing if desired. (This step does not apply to units with built-in interlocking disconnects.)

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 When working on equipment with a built-in interlocking disconnect, keep all personal protective equipment on at all times throughout the troubleshooting and repair/maintenance process. Complete repairs/maintenance on the equipment. Remove all tools and materials from inside the equipment. Close the access door or replace the panel. Remove the lockout device. Stand to one side of the external service disconnect and start the power. (This step does not apply to units with built-in interlocking disconnects.) Ensure that the structural integrity of the equipment (enclosure) is on good condition. Write down any unusual first-time procedures and report them to the supervisor. Give the supervisor a copy of the written procedures. Do not allow unqualified persons to come within 10 feet of any unit that is not in an electrically safe work condition. The equipments door or panel must be closed and there must be no exposed energized parts for an unqualified person to approach. Employers must establish lockout procedures. Minimum lockout procedures: Notify all affected persons that the power to a unit(s) you will be working on will be shut off and that access to the external interlocking disconnect will be locked out. Shut off the power supply to the unit. Attach the proper lockout device and lock to the external interlocking disconnect to prevent anyone from accidentally starting the unit while work is being performed. Attempt to operate the external service disconnect to ensure that the lockout device is working properly. Discharge any stored energy such as the current in the capacitors. Select the properly rated voltage-detecting instrument and check it over carefully for visible damage. Do not use it if there is any indication of damage. Follow company procedures for taking the instrument out of service and select another properly rated, functioning instrument before proceeding. Verify proper instrument operation and test the unit for absence of voltage. Verify proper instrument operation after testing for voltage. Complete maintenance and/or repair on the unit. Verify that the job is complete and remove all tools and materials from the unit. 16

 Notify all affected persons that the lockout has been completed and the electrical supply is being restored. Instruct affected persons to stay away from the unit and electrical supply. Perform any necessary quality control tests or checks on the unit. Remove the lock and lockout device. Notify affected persons that the electrical supply is ready to be returned to normal operation. Turn on the power supply to the unit. Employers must establish hazard/risk evaluation procedures. Minimum hazard risk evaluation procedures: Any time work is performed on or near energized HVAC units that are pushing 480 volts or less, the potential for electrical shock, burns, arc-flash explosions, and other hazards exists. The risk of injury is significant only if the electrical safety programs safe work practices and procedures as described in this program are not followed accordingly. However, in addition to carefully following the safe work practices and procedures established by this program, technicians should inspect/evaluate each unit before starting work. Look for obvious signs of damage to the unit, disconnects (where applicable), and conduit/wiring between service disconnects and the units (where applicable). Look the units over carefully for common causes of arc-flash such as: o Dust and other impurities that could provide a path for electrical current; o Corrosion, which can create impurities on insulating surfaces; o High humidity, rain, or condensation that could result in water vapor on insulating materials, which can cause flashover to ground; o The potential for spark discharge caused by accidental tool or spare parts contacting exposed, energized parts; and o Anything else that could cause arc flash. Report any unusual, potential hazards to your supervisor before proceeding. Affected employers must establish job briefing procedures. Minimum Job Briefing Procedures: A supervisor must conduct a daily, short-term job briefing before the technicians leave the shop for the field. He or she should cover anticipated electrical safety hazards, safe work practices and/or personal protective equipment issues as deemed necessary. 17