2003 Fluke Corporation Electrical measurement safety 1

Electrical measurement safety

Understanding hidden
hazards and new safety
standards

2003 Fluke Corporation Electrical measurement safety 2

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
Goals of this education program
2003 Fluke Corporation Electrical measurement safety 3

Handheld test tool safety
Last known earthly
residence of
automotive fuse
used to replace
original fuse
Test leads survived intact
How not to save time...
2003 Fluke Corporation Electrical measurement safety 4

Handheld test tool safety
Test leads destroyed
13.8 kV
arced
over to
test
probes.
Insides were barbecued.
This DMM had a hot date with 13.8 kV.
2003 Fluke Corporation Electrical measurement safety 5

Handheld test tool safety
Probe tips
burned off
250V fuse
didnt
open in
time
The wrong meter to use on a power circuit.
Poor quality leads and
probes led to injury.
2003 Fluke Corporation Electrical measurement safety 6

Handheld test tool safety
The electrician suffered severe burn
injuries on his hand and arm.
Fingerprints burned
into probes
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Handheld test tool safety
Typical work environment
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Handheld test tool safety
Aftermath of an accident
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Handheld test tool safety
If it melts metal, what does it do to people?
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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
Common DMM / tester hazards
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Three common errors that are avoidable


Common DMM safety hazards
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


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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
Safety inspection
Test leads and probes
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Safety inspection
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?
Checking meter fuses on most meters
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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.


Overload protection on volts inputs
Safety Inspection
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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
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.
Protection against overvoltage transients
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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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Common sense ways to think of categories
Overvoltage category
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
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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!
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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.
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CAT III-
600 V
CAT III-
1000 V
CAT IV-600 V
CAT III-1000 V
Look for CAT III or CAT IV markings
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Levels of CAT III protection
CAT Transient with Fuse and Clearance Creepage
2 Source overload (air) (surface)
Rating
III-1000 V 8000 V 1000 V 16.0 mm 16.0 mm
IV-600 V
III-600 V 6000 V 1000 V 11.5 mm 14.0 mm
II-1000 V
II-600 V 6000 V 600 V 11.5 mm 11.5 mm
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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.
Listed vs. designed to
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Brand A Brand B Brand C
Markings
CAT II 750 V CAT III D of C to
1000 V Input IEC 1010-1
CAT II 1000 V Cat III 1000 V CAT III 1000 V
Creepage
clearance
3.7 mm 2.5 mm 7.5 mm
Doesnt Doesnt Doesnt
comply comply comply
with 5.7 mm with 16 mm with 16 mm
Transient
tests
Input protection Display Input protection
components window components
opened breakdown opened
under high @ CAT II level
voltage
Tested @
But can the product pass testing...
Designed to IEC 1010-1
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1 Flashover inside meter
3 Arcing at the terminals 4 Arc blast
2 Fault current in test leads
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Misuse of DMM in ammeter mode
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Fuse protection on amps inputs
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CAT IV-600 V
CAT III-1000 V
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
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Whats the bottom line?
If you use a scope on power
circuits, you need a CAT III-600 V
scope and scope probes.
Look for the CAT rating and voltage
rating marked near the input jacks.

CAT III-600 V
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CAT IV-600 V
CAT III-1000 V
Whats the bottom line?
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
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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.

Older Fluke
70 Series-III
CAT II-600 V
UNDER RATED
New 170 Series
CAT IV-600 V
CAT III-1000 V
Original
Fluke 70 Series
NOT RATED
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
Min / Max Record
Probe holders
Battery door
What about my old meter?
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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.

2003 Fluke Corporation Electrical measurement safety 36

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.

2003 Fluke Corporation Electrical measurement safety 37

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)

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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.
2003 Fluke Corporation Electrical measurement safety 39

Oscilloscope safety
Category ratings
Select a scope and probes
and clamps for the worst
case category
Voltage ratings
Working voltage
Transient voltage
Overvoltage Working voltage Peak impulse Test source
category (dc or ac rms to grnd) transient (Ohm = V/A)
(20 repetitions)
CAT I 600V 2500 V 30 ohm source
CAT I 1000V 4000 V 30 ohm source
CAT II 600V 4000 V 12 ohm source
CAT II 1000V 6000 V 12 ohm source
CAT III 600V 6000 V 2 ohm source
CAT III 1000V 8000 V 2 ohm source
2003 Fluke Corporation Electrical measurement safety 40

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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Typical use of a differential probe
Oscilloscope safety
Typical use of a differential probe
DC VOLTAGE
DC VOLTAGE
TO MOTOR
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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
2003 Fluke Corporation Electrical measurement safety 43

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
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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
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CAT III circuits - Make sure
you use Cat III leads AND
scope AND current clamp
Oscilloscope safety
Current clamps
Clamps have category and working voltage ratings
Do not exceed them
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CAT III-600 V
Whats the bottom line?
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.
2003 Fluke Corporation Electrical measurement safety 47

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

CAT IV
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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 III
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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

CAT II
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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
CAT I