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A foreword
Commercial and Industrial Wiring is a discipline that requires multiples abilities. Some abilities
are eminently technical, such as the ability to predict circuit’s outcomes, indispensable when
designing or troubleshooting; others closer to the art of craftsmen, such as conduit bending, wire
harnessing, or panel’s arrangements, where although there are techniques to solve problems, the
years of practice make a difference in the quality of the final product.
The intention of this series of tech articles and labs is to expose the student to practical situations
where both phases are present. Along the classes, the student will face straight forward problems
where the solutions are tied directly to the material cover during the lecture, book, and/or the
information into a tech spec or article. Others the student will be exposed to variations of the
same themes, and the basic procedures to achieve a solution will be exposed along the demos,
homework, and labs. These are the real benefits students will receive from this course.
Out of the classroom, in the real world, many times the acquired knowledge will be applied in a
creative way; at that point creativeness, character and experience – things that this course can not
help to develop - will play a roll along knowledge and comprehension, but in today hi-tech fast-
pace environments, it will hardly possible to have chance of building any background,
developing any creativeness, or sharpening any character, without those foundations that the
classroom can deliver.
It’s my wish and hope that this course will become for the students a sort of virtual tool box,
where the inner resources of comprehension might allow them solve practical problems with a
decent level of proficiency, or perhaps, even help them to shine in the workplace.
Adrian De Angelis
MJC – Electronics Department
Instructor
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INDEX
Conduit bending
Glossary of terms and abbreviations 6

90 and Kicks 8
Offsets 10
Back to Backs 12
Saddles 14
Parallel 90ºs 18
Parallel offsets 20
Formulas 21
Summary 22
Greenlee SITE-RITE Hand Bender manual 25
Greenlee 1800 Mechanical Bender manual 33
Ideal Bender Guide 47
Gardner Bender SIDEWINDER Mechanical Bender instruction sheet 51
Safety
Florida Sate University – Department of Environmental Health and Safety 57

Personal Protective Equipment and Clothing 59
Hand Tools 71
Power Tools 83
Technical Articles
AC, MC and HCF cables – FAQ 95

AFC Cable Systems – tyco Electrical and Metal Products
Type of cords 99
How to Select Enclosures 101
Automation Direct
Commercial and Industrial Lighting – Tech Specs 107
Grainger – On-line Catalog No 399
GFCI installation guidelines 111
Pass & Seymour / Legrand
AFCI – Purpose, uses, and general description 149
Consumer Product Safety Commission
UL – AFCI, type and performance considerations (excerpt)
Industrial automation Wiring and Grounding Guidelines 153
Allen Bradley – Publication 1770 – 4.1
Low Voltage Transformer – Selection Guide 173
Square D
UPS Systems – “The Digital World and Electrical Power Supply” 199
General Electric – Consumer & Industrial
PV Systems and the NEC – Suggested Practices 215
John Wiles – Southwest Technology Development Institute – NM (excerpts)
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Grounding Systems – Maintenance and Improvements 231
Joint Departments of the ARMY, NAVY and the AIR FORCE
TM 5-683 / NAVFAC MO-116 / AFJMAN 32-1083
Motors
Tech Specs 237
Grainger – On-line Catalog No 399
Standard Induction Motors 243
Installation, Operation and Maintenance Instruction
Leeson
Electric Motors Maintenance (excerpts) 251
Joint Departments of the ARMY, NAVY and the AIR FORCE
TM 5-864 / NAVFAC MO-200 / AFJMAN 32-1082
Pools 255
New Pool Safety – Senate Bill 873 – 1998 – Guidelines
Electrical Installations in pools – Notes
Hazardous Location Data 261
Hubbell – Killark
Safety Guidelines for the Application, 277
Installation and Maintenance of Solid State Control
Allen Bradley - Publication SGI – 1.1
Diagnosing power problems at the receptacle 303
Fluke – Application Note
Testing Circuit Breakers 307
Meterman – How-to Test it Yourself
Insulation resistance testing 311
Fluke – Application Note
Basic Electronic Troubleshooting Techniques 319
EC&M magazine – John Olobri, AEMC Instruments
Commercial & Industrial Wiring – Lab Guide 325
Lab #1 Bending with Hand Benders – EMT 327

Lab #2 Bending with Mechanic Benders – RMC & IMC 329
Lab #3 Installations using EMT as wiring method 331
Lab #4
#4a 1st part Wiring control circuits 337
#4a 2nd part Wiring a VFD 341
#4b Industrial installations using 365
IMC as wiring method
#4c Frame project 371
Motor control using IMC and FMC as wiring method
Industrial lighting using EMT and FMC as wiring method
Basic circuitry using MC as wiring method
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Conduit Bending
Basic procedures – DO NOT PROCEED BEFORE READING THROUGH A PROCEDURE – Understand first
what is needed to be done, and select the options that suit the best for the situation.
Glossary of basic terms
RUN = Section or sections of conduit used for connecting enclosures, boxes, and/or wiring devices.
MARK = Trace made in pencil or marker as reference to place the bender on the conduit. It is wise to made such
traces all around the conduit and do not erase them until the bend is adequately verified; if adjustments to a
bend is needed, keeping the marks will help to reposition the bender. For exposed work, once the bends are
verify and everything is satisfactory, these traces shall be erased.
STUB = Section of the bend conduit that move off the straight line of the conduit when performing simple bends.
STUB-UP = 90º stub.
TAKE-UP = Amount of inches to be subtracted from the rise measurement in order to place a mark in the stub side
to bend a stub-up. Take-up is also called DEDUCT
LEG = It is the opposite side of the stub.
GAIN = Difference between the total linear length cover by a conduit and the original length of the conduit before
be bent. Usually “GAIN” is referred to stub-ups.
SETBACK = Difference between the take-up and the gain. It is used for finding the stub-up mark from the leg side
by being added to the leg length
KICK = A bend at less than 90º.
OFFSET = Two symmetrical and opposite kicks performed in order to change the plane of a run.
RISE = Amount of inches that is needed to be covered by a bend whether a stub-up, a kick or an offset.
SHRINK = Difference between the original linear length of a conduit and its linear length after a kick or an offset is
performed.
ARC = Section of the conduit that is curve.
BACK-to-BACK = Two or more 90º bends performed on the same conduit.
SADDLE = Three or four kicks performed on a conduit in order to save an obstruction.
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Glossary of abbreviations, parameters and constants
DBM
(a)
STUB
α FST
Offset
(Distance Between Marks)
FST Lth
Length needed for an offset
SNKC
Shrink constant
angle Offset mark
BTB SP
(b) R BM BTB Lth
Back-to- Saddle
LEG Rise BTB mark Length needed for a BTB
Back parameter
GN SNK S SM RC ZC
Gain Shrink Saddle Saddle mark Rise constant Z constant
KP
90 or 90M
STBK Lth Kick parameter ZP
Stb Stub-up
Setback Length of Straight conduit BC Z parameter
Stub mark
BTB constant
TKUP 90 Lth X and Z -for MB-
K KM M
Take-up Length needed for a stub- parameters for pre-
Kick Kick mark Mark
(deduct) up positioning
15º 22.5º 30º 45º 60º

Trade MB RC = 2.61 (2.5 for
RC = 3.86 RC = 2.00 RC = 1.41 RC = 1.15
HB 3 bends Saddles)
size Parameters SNKC = 0.09
SNKC = 0.20
SNKC = 0.27 SNKC = 0.41 SNKC = 0.58
ZC = 3.73 ZC = 1.73 ZC = 1.00 ZC = 0.58

ZC = 2.41
KP 4.4 4.06 3.99 4.13 4.46

½”
SP 0.68 1.03 1.37 2.05 2.73
X = 2.48
BC = 1.12 ZP 3.17 3.52 3.88 4.65 5.48
KP 5.84 5.50 5.50 5.90 6.55

¾”
SP 1.26 1.88 2.51 3.77 5.02
X = 3.18
BC = 2.06 ZP 4.45 5.09 5.76 7.15 8.69
KP 7.63 7.22 7.23 7.72 8.54

1”
X = 4.29 SP 1.58 2.37 3.16 4.75 6.33
BC = 2.6 ZP 5.89 6.71 7.53 9.31 11.25
RC and SNKC are valid for HB as well as Electric Benders
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90ºs
1 From the STUB (a)
a. Mark from conduit end the length of the stub minus the bender’s
DEDUCT
b. Place the mark on the bender’s reference (HB – ARROW, MB –
HOOK external edge)
c. Perform the bend and verify accuracy – Do not erase the mark until the
job is done.
2 From the LEG (b)
a. Mark from conduit end the length of the LEG plus the bender’s
SETBACK
b. Place the mark on the bender’s reference (HB – ARROW, MB –
HOOK external edge)
job is done.
HB Alternative
a. Mark from conduit end the length of the LEG
b. Place the mark on the STAR
job is done.
Kicks
1 Mark from the conduit’s end or from the 90º’s back the distance to perform a KICK at a
given angle to obtain the desired rise (KM form HB or MB, or Y only for MB). See
bender’s chart or formulae at the end of the article.
2 Place the mark on the bender’s reference (HB – ARROW, MB – HOOK external edge)
3 Perform the bend and verify accuracy – Do not erase the mark until the job is done.
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Offsets Up – See illustration
1 Measure from the conduit’s end the distance to the edge of the obstruction minus “X”
when working with MB (See Chart at the end of article). Mark in the conduit – this is
MARK 1 – (Not using X will not affect a good outcome). For HB add SNK or just use
the measurement without adjustments.
2 Mark from MARK 1 the distance between marks for offsets using a given angle – DBM
or L1 for MB – DMB or “center-to-center” distance for HB – This is MARK 2. See
bender’s chart or formulae at the end of the article.
3 Place MARK 1 on the bender’s reference (HB – ARROW, MB – HOOK external edge)
4 Proceed to bend from MARK 1 to MARK 2 – BEWARE the DOG LEG – !!!
5 DO NOT ERASE marks – Verify accuracy
Offsets Down – See illustration
1 Mark from the conduit’s end the distance to the edge of the obstruction minus “Z”
- This is MARK 1 -
For HB subtract DMB + ARC. See formulae at the end of this article.
2 Mark from MARK 1 the calculated distance between marks for offsets using a given
angle – DBM or L1 for MB– This is MARK 2. See formulae at the end of this article.
3 Proceed to bend from MARK 1 to MARK 2 – BEWARE the DOG LEG – !!!
4 DO NOT ERASE marks – Verify accuracy
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Back-to-Back bends
1 First STUB-UP
a. Mark the first stub mark – same procedure used for 90º.
b. Bend the first 90º.
2 Second STUB-UP
A. Without turning the bender – for HB or MB
a. From the back of the 90º mark the BACK-to-BACK distance minus the
bender DEDUCT.
b. Bend the second 90º - BEWARE the bend direction.
c. DO NOT ERASE marks – Verify accuracy
A.1 - MB alternative - Bending Through
i. Place the mark for the first 90º
ii. Using Greenlee’s charts (or using the provided simplified
chats to be used with formulas) place the second mark at L1
(or BM) – Be careful when selecting the height (H); in order
to obtain a “back-to-back” it is necessary make H = BTB –
OD (BTB = Back to Back, OD = Outside Diameter)
iii. Place the mark on the HOOK external edge.
iv. Bend the second 90º - BEWARE the bend direction.
v. DO NOT ERASE marks – Verify accuracy
B. Turning the bender 180º
a. Using HB
i. Proceed to bend the first 90º.
ii. From the back of the 90º, mark the BACK-to-BACK distance
iii. Place the mark on the STAR.
b. Using MB
i. Proceed to bend the first 90º.
ii. From the back of the 90º, place a mark at the BACK-to-
BACK distance + STBK (setback)
iii. Turn the conduit and introduce the straight end on the shoe.
Place the mark on the HOOK external edge.
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Saddles
The best option is to follow the benders’ charts and procedures, but not always this information will be available.
So, how can we lay out a saddle when manuals or charts are not at hand?
Mechanic benders and hand benders will require different approaches, but the basic concept is that saddles are a
combination of offsets. If the sturdiness of the run at the point of a saddle is not an issue, two offsets can be use to
solve the problem easily and fast. But good craftsmanship, as well as sound mechanical installations for electrical
systems - especially in industrial environments, call for saddles made in one piece of conduit.
3 bends saddles are normally used for saving round obstacles, such as steam pipes. 4 bends saddles, instead, are used
for avoiding obstacles that have some considerable width or sharp edges.
Saddles using HBs
3 bends saddles (22 ½ - 45 – 22 ½ )

1 Measure the rise and the distance from the point that is origin of this run to the center of the
obstruction
2 Calculate the shrink (SNK) - based on the 22 ½º -
3 Add SNK to the measurement and use this as the measurement to place the first mark (M1)
4 The other two (M2 and M3) shall be place at DBM from M1 – using RC = 2.5 instead 2.61.
Perform all the bends handle down – BEWARE the DOG LEGS - !!!
Verify all the bends before proceed with the next step
5 Perform the first bend – 45º– at M1 handle up, aligning M1 with the notch mark or the tear drop
mark on the shoe.
6 Perform the second bend – 22½º– at M2 handle down, facing the bender toward M1 and using the
arrow as reference.
7 Perform the second bend – 22½º– at M3 handle down, facing the bender toward M1 and using the
arrow as reference.
4 bends saddles
1 Measure the rise and the distance from the point that is origin of this run to the first edge of the
obstruction, and the width of the obstruction.
2 Place Ma at the edge of the obstruction plus the shrink
3 Place Mb at DBM back from Ma toward the beginning of the conduit.
4 Place Mc from Ma at a distance equal to the obstruction’s width.
5 Place Md at DBM from Mc.
6 Put Ma at the arrow with Mb in the back of the shoe. Perform the first bend
7 Slide the conduit forward and place Mb at the arrow, rotate conduit 180º and perform the second
bend
8 Turn the bender head facing the opposite direction
9 Put Mc at the arrow; now Md should be in the back of the shoe. Perform the third bend.
10 Slide the conduit forward placing Md at the arrow. Rotate conduit 180º and perform the last bend
– extend the stub with a piece of conduit of larger size if the stub is too short to have enough
leverage.
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Saddles using MBs
3 bends saddles
1 Measure the rise and the distance from the point that is origin of this run to the center of the
obstruction
2 Select the first angle as the angle of the saddle – the middle angle will be double than this first
one. Then the saddles can be made 15º- 30º- 15º, 22½º - 45º - 22½º, or 45º - 90º - 45º.
3 Using values on the “Bend Types” table, and based on conduit size and angle selected,, calculate
Z, DMB, and SM
4 Place marks at Z (Ma), DBM (Mb), and SM (Mc) consecutively and in this order from the end of
the conduit
5 Perform all the bends from the first mark to the last one using the external edge of the hook as
reference and rotating the conduit 180º after each bend.
4 bends saddles
1 Measure the rise and the distance from the point that is origin of this run to the first edge of the
obstruction, and the width of the obstruction.
2 Select the angle to be used for the saddle
3 Using values on the “Bend Types” table, and based on conduit size and angle selected,, calculate
Z, DMB, and SM
4 Place a mark at Z from the end of the conduit (Ma)
5 Place a mark at DMB from Z (Mb). Also from Z place another mark at width + SM (Mc).
6 Place the last mark (Md) at DBM from Mc
7 Perform all the bends from the first mark to the last one using the external edge of the hook as
reference and rotating the conduit 180º after each bend.
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Parallel 90º
Without changing the radius

1 Measure the shortest stub
2 Add the distance between conduits (top to top or back to back) to the next stub
3 For several conduits multiply the distance between conduits by the number of conduits minus 1 in
order to increase progressively the length of the stubs.
4 Subtract to each stub the take-up of the bender
5 Perform all the bends. When in place all the stubs will end on the same line
In order to obtain equal results with the legs all the bends will need to be pre-cut
1 Measure the shortest stub and leg, add them and subtract the gain – This is the length of the
shortest run
2 Add twice the distance between conduits (top-to-top, or back-to-back), then subtract the gain –
This is the length of the next run
3 Repeat the procedure for as many conduits will be laid parallel
4 Mark the stubs as indicated before
5 Proceed to bend all the conduits. When placed in position all the stubs and legs will coincide in the
same line – no staggering.
Changing radius
The difference with the former procedures is that the parallelism will be kept also in the area of the curve.
The first run will be made with the regular radius of the bender’s shoe
The next runs have to add the distance between conduits to the radius in the 90º, therefore segment bending
will be needed.
If only two ½ “ or two ¾ “ conduits are going to be run parallel, and the distance between bends is not
relevant, an alternative is to make the first 90º in the ¾ “ shoe and the other in the 1” shoe.
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Parallel Offsets
If the crowding in the offset area is not an issue, just move the marks SNK forward in each conduit to avoid
staggering the ends
If the crowding has to be avoided (more professional solution,) marks have to be moved SNK * distance between
conduits.
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DEPARTMENT
OF
ENVIRONMENTAL HEALTH AND SAFETY
PERSONAL PROTECTIVE EQUIPMENT AND CLOTHING GUIDELINES
HAND TOOLS GUIDELINES
POWER TOOLS GUIDELINES
Look for more resources at www.safety.fsu.edu
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Personal Protective Equipment and Clothing Manual
Table of Contents
• Purpose
• Responsibilities
• Specific PPE;
1. Head Protection
2. Foot Protection
3. Eye and Face Protection
4. Hand Protection
5. Body Protection
6. Fall Protection
7. Respiratory Protection
8. Hearing Conservation
• Care and Maintenance
• Training
• Recordkeeping
• References
Purpose
It is the intent of The Florida State University (FSU) to provide every

employee with a safe and healthful working environment. Any faculty or staff
member who needs protection during the course of their employment
activities, should be protected by PPE.
Where feasible, appropriate engineering and/or administrative controls will

be utilized to reduce or eliminate employee exposure to work place hazards.
Where engineering or administrative controls are not feasible or
supplemental protection is desired, PPE shall be utilized by employees.
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Responsibilities
This manual has been developed by the Department of Environmental Health

& Safety (EH&S). The Coordinator, EH&S, Industrial Hygiene (Industrial
Hygiene Coordinator) is charged with administering the Program for FSU.
The Industrial Hygiene Coordinator will review this procedure for
effectiveness and verify the use of PPE by FSU personnel in accordance with
this procedure.
A Hazard Assessment of the workplace shall be conducted by the Supervisor

to determine if hazards are present, or are likely to be present, which
necessitate the use of PPE. The Industrial Hygiene Coordinator will assist
with Hazard Assessments upon request. Basic hazard categories include:
• Impact
• Penetration
• Compression (roll-over)
• Chemical
• Heat
• Harmful dust
• Light (optical) radiation
Supervisors shall inform employees of the PPE necessary for specific tasks
assigned and shall ensure that workers receive the training required as
outlined in this manual.
The Industrial Hygiene Coordinator will assist the supervisor/user employee

in choosing and fitting PPE, upon request.
Supervisors shall ensure that employees wear the appropriate PPE.
Employees shall be responsible for properly donning, doffing, wearing,

inspecting, cleaning, and storing all assigned PPE.
Training will be provided or contracted by EH&S.
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Specific PPE
This section describes the specific PPE required for work operations at FSU.
Selection of PPE shall be based on a hazard assessment of the work to be
performed and the area in which the work is to be performed.
1. Head Protection
Employees shall wear protective helmets when working in areas where

there is a potential for injury to the head from falling objects (Class A,
B, and C hard hats) and from electrical shock (Class A and B only).
Hard hats shall comply with ANSI Z89.1-1986, "American National
Standard for Personnel Assurance Protection-Protective Headwear for
Industrial Workers-Requirements."
The entire hard hat (helmet) should be replaced when the shell shows
signs of damage, wear, or has been subjected to an impact that would
lessen the integrity of the hard hat. Drilling holes in the shell of a hard
hat eliminates the electrical insulation protection and the degree of
impact resistance. Wearing head protection properly is essential, if the
head protection is not worn as designed, it may not offer the level of
protection for which it was designed.
2. Foot Protection
Personnel shall wear adequate foot protection when working in areas

where there is a danger of foot injuries due to falling or rolling objects,
or objects piercing the sole, where an employee's feet are exposed to
electrical hazards, and where there is a slipping hazard. Protective
footwear shall comply with ANSI Z41-1991, "American National
Standard for Personal Protection-Protective Footwear".
Open-toed shoes, sandals, flip-flops, etc. shall not be worn into any
area where there is a potential for foot injury.
Employees and students shall use appropriate eye or face protection

when working with liquid chemicals, acids, caustic liquids, chemical
gases or vapors, molten metal, cryogenic liquids, potentially injurious
light radiation, welding, and flying objects/particles. The selection and
use of eye protection shall be based on the hazard identified during
the hazard assessment. Contact EH&S for assistance in selecting
proper protective eyewear.
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Protective eye and face equipment shall comply with ANSI Z87.1-
1989, "American National Standard Practice for Occupational and
Educational Eye and Face Protection". "Z87" and the name of the
manufacturer shall be stamped on the frame.
Eye protection shall be worn in areas identified as containing the

potential for eye injury and when performing work tasks with potential
eye hazards.
Prescription safety glasses shall be provided to those employees that

require prescription glasses when they are assigned to work in
potentially hazardous locations. These safety glasses shall be provided
at no cost to the employee.
Personnel wearing contact lenses shall exercise extreme care when

working with liquid chemicals, gases, or vapors. Eye protection shall be
selected using the same criteria for non-contact wearing personnel.
Non-gas permeable contact lenses shall not be worn in these types of
operations due to the increased risk of eye injury in the event of an
exposure to a chemical.
The selection of protective eyewear (filter lenses and plates) for

welding, cutting, and brazing shall be based on ANSI Z87.1-1968,
"American National Practice for Occupational and Educational Eye and
Face Protection". Contact EH&S or see the table in OSHA 1910.252 for
assistance.
The selection of protective eyewear for laser users shall be based on

ANSI Z136.1-1993, "American National Standard for Safe Use of
Lasers". Consideration of optical density, laser medium, wavelengths
and power output shall be reviewed. Contact EH&S, Radiation Safety
Office for assistance in selecting this type of protective equipment.
4. Hand Protection
Employees shall use appropriate hand protection when hands are

exposed to potential hazards such as those from skin absorption of
harmful substances, contact with acids or caustics, severe cuts or
lacerations, abrasions, punctures, electrical/thermal/chemical burns,
and harmful temperature extremes.
There is no single glove which provides protection against all potential

hand hazards, and commonly available materials provide only limited
protection against chemical and physical hazards.
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It is important to select the most appropriate glove for a particular
application and to determine how long it can be worn effectively.
Consider work activities, degree of dexterity required, duration,
frequency, degree of exposure, physical stresses, and toxic properties
of chemicals.
When working with liquid hazardous chemicals, gloves such as rubber,

nitrile, neoprene, PVC, butyl rubber, latex shall be selected based on
permeability, toxicity, and corrosivity of the material. Refer to the FSU
Chemical Hygiene Plan for a detailed Glove Selection Chart or contact
EH&S or the manufacturer for assistance.
Leather or cotton gloves shall be worn when there is a potential for

injury from being struck against, caught between, cut, or punctured;
and materials handling. These types of gloves shall not be worn for
protection from liquid or hazardous materials.
Gloves designed to protect from temperature extremes shall be worn

when handling and transferring cryogenic gases and liquids, and when
operating high temperature equipment such as furnaces and ovens.
Gloves may be specially designed cryogenic gloves, leather, or other
suitable (non-asbestos) materials with proper insulating properties.
Electricians shall wear insulated rubber gloves meeting the

requirements of ASTM D120-87 when working with high voltage
equipment. These gloves may be worn under leather gloves to prevent
punctures. A daily visual inspection must be performed and any
damaged (hole, tear, puncture, cut, texture changes, embedded
object, etc.) glove shall not be used.
Gloves should not be worn when operating equipment such as drill

presses, lathes, or other equipment with exposed rotating parts. In
these instances, the gloves may be entangled in the moving parts
causing injury.
5. Body Protection
A large variety of chemical protective clothing (CPC) types and

materials are available for use in the protection of the body from
hazards of chemicals and work conditions. Proper selection is based on
the type of chemical or work task to be encountered. Contact EH&S for
assistance in the selection of CPC.
Coveralls provide total body protection from potential exposure to

hazards. There are many types of materials available based on the
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hazards involved. Coveralls should be worn when there is an
immediate danger from exposure to the hazard involved.
Splash suits and aprons are available for protection against hazards
from liquid materials where there is a lesser degree (than above) of
danger from exposure to the material.
Lab coats should be worn in all laboratories where hazardous

chemicals or processes are present. Lab coats provide protection to
the individual from minimal exposures to hazardous materials. Lab
coats should be removed before leaving the area and stored in a
location to keep them clean. Lab coats should be commercially
laundered.
All CPC shall be removed before leaving the assigned work area.
Disposable CPC shall be properly disposed of in accordance with the
FSU Chemical Hygiene Plan. Non-disposable or re-usable CPC is to be
stored in a designated area.
6. Fall Protection - Personal Fall Arrest Systems
Each employee on a walking/working surface (horizontal and vertical

surface) with an unprotected side or edge which is 6 feet or more
above a lower level shall be protected from falling by the use of
guardrail systems, safety net systems, or personal fall arrest systems.
Exceptions to using personal fall arrest systems:
o When employees are making an inspection, investigation, or

assessment of workplace conditions prior to the actual start of
work or after all work is completed.
o When employees are working from a ladder. Fall protection
requirements for employees working from a ladder are located in
OSHA 29 CFR 1926, Subpart X.
o When employees are working from certain types of scaffolds. Fall
protection requirements for employees working from a scaffold
are located in OSHA 29 CFR 1926, Subpart L.
o When guardrail or safety net systems are being utilized for fall
protection. Requirements for guardrail and safety net systems
are located in OSHA 29 CFR 1926, Subpart M.
Personal fall arrest systems consist of a full body harness (body belts
are prohibited), a shock-absorbing lanyard, and a lifeline if applicable.
Only locking type snaphooks shall be used as part of a personal fall
arrest system. Lifelines are also necessary in certain types of work
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such as Confined Space Entry or when working in trenches or
excavations. Refer to the Confined Space Entry Section of the Safety
Manual for further information.
Harnesses, lanyards and lifelines shall be used only for employee

protection. (not for hoisting materials etc.)
Personal fall arrest systems and components subjected to impact

loading shall be immediately removed from service and shall not be
used again for employee protection.
Personal fall arrest systems shall be inspected prior to each use for
wear, damage and other deterioration, and defective components shall
be removed from service.
7. Respiratory Protection
Respiratory protective devices shall be worn when the use of

engineering controls (fume hoods, exhaust systems, ventilation,
isolation, etc.) do not reduce the contaminant levels below the
established OSHA permissible exposure limit (PEL), in emergency
response actions, and for voluntary use if exposure is below the PEL.
Employees that are required to wear respiratory protective equipment

shall be trained and have medical approval to wear a respirator prior
to using respiratory protection. (exception: nuisance dust masks)
Refer to the Respiratory Protection Section of the Safety Manual for
further information.
8. Hearing Conservation
Hearing protection is required in areas where the sound level exceeds

an 8-hour time-weighted average of 85 decibels. These areas shall be
posted, if feasible, and hearing protective devices shall be readily
available for use by personnel and visitors. Hearing protective devices
include earplugs and muffs.
Employees that are required to wear hearing protective equipment

shall be trained and have an audiogram prior to using hearing
protection equipment. Refer to the Hearing Conservation Section in the
Safety Manual for further information.
- 65 -
Care and Maintenance
Personal protective equipment requires proper cleaning, decontamination,

inspection, repair, replacement, and storage. Always follow the
manufacturer's instructions. Never use damaged or defective PPE.
1. Head Protection
Cleaning and decontamination includes the washing of equipment with

a mild detergent or bleach solution to prevent the spread of head lice,
mites, etc. if equipment is shared. This should be done prior to
storage.
Inspections shall be done prior to each use. Check for proper fit.
Insure that there are no cracks, dents, holes, or gouges in the hat.
Check all inner fitting straps and adjusting devices. Inspect the hat for
signs of contamination or degradation due to exposure to chemicals.
Repairs by a competent person shall be made to any defective

equipment before use. If repairs cannot be made, replace that piece of
equipment with an approved device.
Store in a clean, dry place.
2. Foot Protection
Inspect foot protection monthly, checking for tears, holes, and other
defects.
Keep footwear as clean as possible. For leather boots, clean and oil
them monthly.
Inspect eye and face protection before each use. Inspect for cracks,
tears, scratches that would impair eyesight, and other defects.
Clean eye and face protection with mild soap and water. Do not use
ammonia, alkaline cleaners, abrasive cleaning compounds, or solvents.
- 66 -
4. Hand Protection
Inspect gloves before each use. Check for holes, cracks, tears and
other damage.
Cleaning and decontamination of gloves is normally accomplished by

discarding after use. Leather and thermal protection gloves should be
re-used, keeping them as clean as possible.
5. Body Protection
Inspect chemical protective clothing before each use. Check for tears,
holes, degradation, defects, or other damage.
Most CPC is disposable and should be properly discarded after use.

Non-disposable CPC shall be properly decontaminated after each use.
Lab coats and other CPC should be laundered by a commercial
laundry.
6. Fall Protection
Inspect personal fall arrest systems before and after each use. Check
for damage, defects, and degradation. Be sure to check connection
points such as buckles, D-rings, etc.
Keep fall protection equipment as clean as possible to facilitate

inspection of the equipment.
- 67 -
Training
All employees required to wear PPE shall be properly trained.
The training will include, but is not limited to, the following:
• When PPE is necessary.

• What PPE is necessary.
• How to properly don, doff, adjust, and wear PPE.
• Limitations of the PPE.
• The proper care, maintenance, useful life and disposal of the PPE.
Each affected employee shall demonstrate an understanding of the training

and the ability to use PPE properly, before being allowed to perform work
requiring the use of PPE.
Retraining is required when:
• Any affected employee who has already been trained does not have
the understanding and skill to wear the assigned PPE properly.
• Changes in the workplace render previous training obsolete.
• Changes in the types of PPE to be used render previous training
obsolete.
Recordkeeping
EH&S will retain training documentation.
Individual departments will retain documentation of hazard assessments of

the workplace, that will include: identification of the workplace evaluated,
the person certifying that the evaluation has been performed, and the
date(s) of the hazard assessment(s).
- 68 -
References
1. Occupational Safety and Health Administration (OSHA) 29 CFR,

Subpart I - Personal Protective Equipment, 1910.132-.138, 1998;
Subpart M - Fall Protection, 1926.500-.503, 1998 and Subpart Q -
Welding, Cutting and Brazing, 1926.252, 1998.
2. OSHA Auditing: Federal Compliance Guide, STP Specialty Publishers,
Inc., 1996
3. Collective Bargaining Agreement; Florida Public Employees Council 79;
American Federation of State, County and Municipal Employees, July
1, 1996 through June 30, 1999
4. Florida Administrative Code 38I-20, Safety and Health Standards
- 69 -
- 70 -
Hand Tools Manual
Table of Contents
• Introduction
• General Requirements
• Specific Recommendations for Safe Use of Hand Tools
• Appendix 1: Checklist
Introduction
Frequent and severe injuries caused by the abuse and neglect of hand and
powered tools dictate that control and maintenance of tools be made a part
of the University safety program. The correct tool must be selected for each
job. Examples of unsafe practices include striking together hardened faces of
hand tools; using a file or a screwdriver for a pry; using a wrench for a
hammer; and using pliers instead of the proper wrench.
Tools should be kept in good condition. Examples of unsafe tools include

wrenches with cracked or worn jaws, screwdrivers with broken points or split
or broken handles, hammers with loose heads, broken or split handles,
mushroomed heads on chisels, and dull saws.
- 71 -
General Requirements
Good Condition of Tools
Supervisors are required to ensure that all tools used by the employees,
including tools and equipment furnished by the employees, are in a safe
condition.
Safety Procedures and Tool Inspection
Procedures for the care, inspection, and safe use of all tools must be
established and the supervisor is responsible for implementing a program
whereby all employees using tools follow those procedures.
Personal Protective Equipment
Appropriate eye protection must be worn by all workers using hand tools
which may generate sparks and/or airborne particles.
Spark resistant tools made of nonferrous materials should be used in

environments that contain high levels of explosive substances.
Housekeeping
Toolboxes, tool racks or shelves, or other such storage devices must be

provided and tools not in use must be safely stored in them.
Metal slivers, wood slivers, sawdust, moisture and grime should be removed
from tools before they are stored. Never remove these particles with bare
hands.
- 72 -
Specific Recommendations for Safe Use of Hand Tools
Impact Tools (chisels, punches, hammers)
Hammer-struck and striking tools should be made of forged, hardened steel

so that they are hard enough to withstand blows without mushrooming
excessively, and yet not be so hard that they chip or crack.
Never carry chisels, punches and other sharp tools in clothes pockets. Use
carrying pouches that will fasten around the waist.
Chisels should be kept sharp and ground to a 60-degree angle. Mushroom

heads should be ground off.
Eye protection must be worn when using chisels and punches. A shield or
screen should be used to prevent injury to other workmen from flying
particles.
Hammers must have securely wedged handles suited to the type of head
used. The handle should be smooth, free of oil, shaped to fit the hand, and
properly sized for the job.
Carpenter's or claw hammers are designed primarily for driving and drawing
nails, and they are unsuitable for striking heavier objects, such as cold
chisels. The corners of the claw should not be used as pries because they are
susceptible to chipping and breaking.
Wrenches
There is a correct wrench for every nut and bolt. Oversize openings will not
grip the corners securely and shims should not be used to compensate for an
oversized opening. Using the wrong size wrench can round the corners of the
bolt, or cause slippage, as well as make it difficult to then apply the proper
size.
Remove caked dirt and grime from inside sockets to allow them to seat fully.
Never overload the capacity of a wrench by using a pipe extension on the

handle or strike the handle of a wrench with a hammer.
Adjustable wrenches are generally recommended for light-duty jobs or when

the proper size, fixed-opening wrench is not available. Caution must be
exercised in using these wrenches, as they are likely to slip because of the
- 73 -
difficulty in setting the correct size and the tendency for the jaws to "work"
as the wrench is being used.
Prevent serious injuries by being careful not to allow pipe wrenches to slip on
overhead pipes or fittings causing loss of balance and falls.
Machine wrenches are often incorrectly used as hammers. As a result, they

soon become distorted and unsafe. Always use the proper tool for the job.
Screwdrivers
Screwdrivers must never be used as punches, wedges, pinch bars or pries.

They are easily damaged causing blades to slip off the slots and injure
workers' hands.
A screwdriver tip should fit the screw. A sharp square-edged bit will not skip
as easily as a dull, rounded one, and it requires less pressure. The tip must
be kept clean and sharp to permit a good grip on the head of the screw.
The part being worked should never be held in the hand. It should be laid on
a bench or flat surface, or held in a vise.
Screwdrivers having blades or rivets extending through the handle should

never be used for electrical work. Both blade and handle should be insulated
except the tip.
Bladed Tools (knives, axes, wedges)
Many accidents have been caused by bladed tools (knives, axes, wedges)
being used in an unsafe manner. Unsafe practices include: knives carried in
pockets, or placed in toolboxes or on workbenches; axes used for
sledgehammers, or with loose handles; wedges struck with a glancing blow
becoming unguided projectiles.
Knives are more frequently the source of disabling injuries than any other
hand tool. The principal hazard in the use of knives is the hand slipping from
the handle onto the blade. The following safety procedures should be
followed:
• The cutting stroke should be away from the body. If that is not
possible, then the hands and body should be in the clear;
• Workmen who must carry knives with them on the job should keep
knives in sheaths or holders. Never carry a sheathed knife on the front
part of a belt. Always carry it over the right or left hip, toward the
back. This will prevent severing a leg artery or vein in case of a fall;
- 74 -
• Never attempt to catch a knife when it falls. Let it drop to the ground,
and then pick it up by the handle.
To use an axe safely, workers must be taught to lift it properly, to swing

correctly, and to place the stroke accurately. The proper grip for a right-
handed person is to have the left hand about 3 inches from the end of the
handle, and the right hand 3/4 of the way up on the handle. A left-handed
person should reverse the position of the hands.
An axman must make sure that he has a clear circle in which to swing the
axe before he starts chopping. Also, he should remove all vines, brush, and
shrubbery within the range. Overhead vines that may catch or deflect the axe
must be removed. It is also advisable to wear safety shoes and protective
eyewear when using an axe.
The use of wedges should be discouraged whenever possible (i.e., when

splitting wood). The use of a maul is more effective and less dangerous.
When wedges are struck with a hammer, the head of the hammer may be
released from the shaft and travel some distance, possibly striking someone
and causing injury. Safety shoes and protective eyewear should be worn if a
wedge must be used.
Pliers and Nippers
Pliers are often considered a general-purpose tool and are often used for
purposes for which they were not designed. Pliers are meant for gripping and
cutting operations. They are not recommended as a substitute for wrenches
because their jaws are flexible and frequently slip and do not hold the work
securely.
The handle of electricians' pliers should be insulated. In addition, users

should wear electricians' gloves.
Nippers sometimes cause injuries when they are used to cut short ends of
wire. The following safety precautions should be followed:
• Use only insulated nippers when working with electrical equipment;

• Special cutters for heavy wire, reinforcing wire, and bolts should be
used in lieu of makeshift tools (claw hammers, pry bars);
• Appropriate eye protection should be worn when using nippers to
prevent injury from flying short ends of wire.
- 75 -
Vises
Vises are used for holding material while it is being worked. Material can be
securely clamped in the jaws of a vise and held while the work is performed.
The handle used to tighten the jaws of the vise should not be struck with a
hammer to gain additional holding strength. Tighten with hands only.
When striking material held in a vise, eye protection must be worn in

accordance with OP-G-1.1.2.3.
Saws
Saws should be properly selected for the job. Use a cross cut for cutting
across the grain; a ripping saw should be used for cutting with the grain.
Saws must be kept sharp and the teeth kept well set to prevent binding.
Hacksaws should be adjusted in the frame to prevent buckling and breaking,

but should not be tight enough to break off the pins that support the blade.
Install blades with teeth pointing forward.
Crowbars
When a crowbar is needed, the proper size and kind of bar for the job should
be used. Makeshifts, such as a piece of pipe or an iron bar, should never be
substituted for a crowbar since they may skip and cause injury.
The crowbar should have a point or toe of such shape that it will grip the
object to be moved, and a heel to act as a pivot or fulcrum. In some cases, a
block of wood under the heel will prevent the crowbar from slipping and
injuring the hand.
Do not leave crowbars lying on shop floors or work areas; they may cause a
tripping hazard.
Jacks
The rated load must be legibly and permanently marked on every jack. The
operator must use the jack according to manufacturers instructions, never to
exceed the rated load.
Jacks must be blocked when positioned on foundations that are not firm. A
block must also be placed between the cap and the load where there is a
possibility of slippage.
- 76 -
The jack operator must ensure that the stop indicator is clearly visible and
that he does not exceed the limit.
After the load has been raised, it must be cribbed, blocked, or otherwise
secured.
Jacks must be properly lubricated at regular intervals. Hydraulic jacks that

are exposed to freezing temperatures must be supplied with an adequate
antifreeze liquid.
- 77 -
Appendix 1: Checklist
A checklist of questions to survey for hand equipment problems should be

tailored to each of your operations. Some of the items may include:
General Requirements Yes No

Good Condition of Tools
Does the supervisor regularly check to ensure that all
tools are kept in a safe condition?
Safety Procedures and Tool Inspection
Has a procedure for the care, inspection, and safe use
of all tools been established and made available to all
employees?
Is appropriate eye protection available and its use
required when hand tools may produce sparks or
airborne particles?
Are spark resistant tools of nonferrous available for
work in environments which may contain high levels of
explosive substances?
Housekeeping
Is there adequate storage room provided and is it
required that tools not in use be safely stored?
Is it required that employees remove slivers, sawdust,
moisture and grime from all tools prior to their being
stored?
Specific Recommendations for Safe Use of Hand Yes No
Tools
Impact Tools (chisels, punches, hammers)
Are hammer-struck and striking tools made of forged,
hardened steel to withstand blows, yet not so hard
they chip or crack?
Are carrying pouches available so that chisels,
punches or other sharp tools can be safely carried
around the waist?
Are tools and equipment (both University and
employee-owned) in good condition?
- 78 -
Have mushroomed heads on chisels, punches, etc.,
been reconditioned or replaced if necessary?
Are chisels kept sharp and ground off to a 60-degree
angle?
Do hammers have securely wedged handles? Are the
handles smooth, clean, and fitted to the job?
Is it required that claw hammers be used only for
driving or drawing nails and never for other purposes?
Have broken hammer handles been replaced?
Wrenches
Is an assortment of wrenches available to ensure that
the correct size is available for every job?
Are employees required to remove dirt and grime from
wrench sockets?
Have employees been cautioned to never use pipe
extensions to extend the capacity of a wrench or to
never strike a wrench handle with a hammer?
Are employees carefully trained on the use of
adjustable wrenches to avoid their slipping if the
"jaws" should slip?
Are employees warned of the dangers of pipe
wrenches slipping on overhead pipes, leading to
serious falling injuries?
Is it forbidden to use machine wrenches as hammers,
thus leading to their becoming distorted and unsafe?
Is it prohibited to use screwdrivers for other than their
intended purpose?
Are employees required to keep screwdriver tips clean
and sharp?
Are vises available to hold work?
Are employees aware of the dangers of holding an
object on which s/he is working?
Are screwdrivers with blades or rivets extended
through the handles prohibited for electrical work?
Have worn or bent wrenches been replaced?
- 79 -
Bladed Tools (Knives, Axes, Wedges)
Are employees alert to the following dangers:
• Knives carried in pockets?
• Knives placed upright in toolboxes or on
workbenches?
• Using axes for sledge hammers?
• Using axes with loose handles?
Are employees who use knives aware that most accidents with knives
could have been avoided by:
• Cutting away from the body?
• Keeping the hands and body clear from the blade?
• Keeping the knife in a sheath or holder, carried over
the right or left hip, toward the back?
• Never attempting to catch a falling knife?
Are employees who work with axes trained in proper,
safe grip method?
Prior to beginning work with the axe, do employees
clear the area to give him/her a clear circle in which to
swing the axe?
Is the use of wedges discouraged?
Is a maul available and its use required to avoid
having to use wedges?
Are safety shoes and protective eyewear available and
their use required if a wedge must be used?
Pliers and Nippers
Is the use of pliers for other than their intended
purpose prohibited?
Are the handles of electricians' pliers insulated? Are
electricians' gloves provided and their use required?
Are the following safe practices required when employees use
nippers:
• The use of only insulated nippers when working
with electrical equipment?
- 80 -
• Are special cutters supplied for heavy wire, and the
use of claw hammers and pry bars prohibited for
cutting wire or bolts?
• Is appropriate eye protection provided and its use
required to prevent injury from flying short ends of
wire?
Vises
Are appropriate and sufficient vices provided to hold
material while it is being worked?
Are employees prohibited from holding material in the
bare hand while working it?
Is it forbidden to strike the jaws of a vise by striking
with a hammer? Is tightening allowed with the hands
only?
Is eye protection provided and its use required in
accordance with OP-G-1.1.2.3?
Saws
Are employees trained on which saw to use for specific
jobs?
Are saws kept sharp and the teeth kept well set to
prevent binding?
Have hacksaws been adjusted in the frame to prevent
buckling and breaking? Are they not so tight that there
is danger breaking off? Are blades installed with the
teeth pointing forward?
Crowbars
Are there sufficient crowbars available to ensure that
the proper size and kind is available for any job which
may be performed?
Is the use of makeshift crowbars prohibited?
Do all crowbars have a point or toe shaped to grip the
object to be moved, and a heel to act as pivot or
fulcrum?
Is it required that crowbars be returned to storage
after use, to preclude their becoming a tripping
hazard?
- 81 -
Jacks
Is the rated load legible and permanently marked on
every jack?
Are all operators prohibited from exceeding the rated
load?
Are blocks available when the jack must be used on
foundations that are not firm?
Do all jack operators ensure that the stop indicator is
clearly visible and do they know they should never
exceed the load?
Is material available to cribb, block, or otherwise
secure the load after it has been raised?
Are jacks kept properly lubricated?
Are hydraulic jacks that may be exposed to freezing
weather supplied with adequate antifreeze liquid?
- 82 -
Power Tools Manual
Table of Contents
• General Requirements
o Power Controls
o Safe Electrical Connections
o Guarding
o Personal Protective Equipment
o Housekeeping
o Safety Procedures and Training
• Specific Recommendations for Safe Use of Portable Power Tools
o Electrically Powered Tools
o Air Powered Tools
o Gasoline Powered Tools
o Torches
o Explosive Actuated Tools
• Appendix 1: Checklist
- 83 -
General Requirements
Power Controls
All hand-held powered tools must be equipped with a positive on/off control or
other controls such as:
• A constant pressure switch or control ("dead man's switch") that will shut off
the power when the pressure is released (i.e., portable circular saws,
portable power drills, and disc sanders with discs greater than 2 inches);
• A constant pressure throttle that will shut off the power when the pressure is
released (i.e., gasoline powered chain saws);
• A lock-on control that allows the power to be discontinued by a single motion
of the same finger or fingers that turned it on.
The operating control on hand-held power tools must be located as to minimize the
possibility of its accidental operation, if such accidental operation would constitute a
hazard to employees.
Safe Electrical Connections
Before using portable power tools, inspect wiring to ensure it is not broken, loose or
frayed. If such is found, equipment must be removed from service immediately and
repaired.
Only low voltage electrically powered tools are authorized for use in tanks and wet
areas.
Only explosion proof electrically powered tools are authorized for use in
environments where flammable gases, highly volatile liquids, and other explosive
substances are stored or used.
Electrically powered tools must be powered by an electrical source that is

continuously grounded. If necessary, three-wire plug extension cords or ground
wire fasteners must be used. Extension cords must be properly sized to the wattage
of the power tool.
Electrical defects or minor shocks must be reported to the supervisor.
Electric cords should not be placed where individuals may trip on them or cause the
power tools they serve to be jerked from the operators, resulting in injury to the
operator.
Guarding
All portable, power-driven saws with a blade diameter greater than 2 inches must
be equipped with guards above and below the base plate or shoe. These guards
- 84 -
must cover the saw to the depth of the teeth. When the tool is withdrawn from the
work, the lower guard must automatically return to the covering position.
Portable abrasive wheels and portable grinders must be guarded on top, sides and
bottom of the wheel. The guards must be secured by a fastening in excess of the
strength of the guard and the guard must be properly aligned with the wheel at all
times during use.
Scratch brushes used on portable power tools should be permanently guarded in

the same manner as grinding wheels.
Fastening tools that are actuated by explosive charges must be guarded at the
muzzle end. The guard should be at least 31/2 inches in diameter and completely
shield the barrel.
Other appropriate guards must be provided to protect the operator and other
employees from hazards such as exposed belts, exposed rotating parts, flying chips
and sparks.
No employee shall operate and/or cause to be operated any portable power tool
without the prescribed protective devices in place.
Appropriate eye protection must be worn by all operators and helpers where the
operation of the tools may produce flying objects or dust.
Hearing protection must be utilized for jobs that involve the risk of loss of hearing.
Personnel must not wear loose fitting clothing, long hair or jewelry when working
with power tools with revolving parts such as drills, saws, and grinders.
Safety shoes are recommended for wear by those who use power tools of
significant weight that may injure the operator if the tool should fall or be dropped.
When power tools are used in overhead places, the operator should wear a safety
belt or shoulder to minimize the danger of falling should the tool break suddenly or
shock the operator.
Approved dust-type respirators should be worn on buffing, grinding, sanding or

mixing jobs where harmful dusts are produced.
Housekeeping
Metal slivers, sawdust and other debris should be cleaned from the machine using a
brush or rag. Never use bare hands for the task. NEVER clean a machine while it is
in motion.
- 85 -
Compressed air may be used for cleaning purposes only where reduced to less than
30 P.S.I. Eye protection must be worn while using compressed air to clean
equipment.
Oily rags, waste, and other materials saturated with combustible substances must
be disposed of in approved metal containers equipped with self-closing lids. These
containers should be clearly marked for disposal of oily waste materials and must
be emptied on a daily basis.
Local exhausts should be installed on machines where large amounts of dust are
produced, such as sanders and planers.
Safety zones surrounding machines should be established and marked. Machines

should be spaced to allow for the establishment of safety zones.
Safety Procedures and Training
The operators of portable power tools must be thoroughly trained in the safe
operation of the tools. All manufacturers manuals and diagrams should be kept by
the shop supervisor and made available to employees responsible for operating the
tools. The shop supervisor should contact the manufacturers in writing or contact
the Department of Environmental Health and Safety if insufficient information on
the tools could result in their unsafe operation.
Procedures for the care, inspection, and safe use of all power tools shall be
established and the supervisor is responsible for implementing a program whereby
all employees using tools follow these procedures.
It is the supervisor's responsibility to ensure that appropriate procedures are

followed.
- 86 -
Specific Requirements for Safe Use of Portable Power Tools
Portable power tools are divided into five primary groups according to the power
source: electric; pneumatic; gasoline; hydraulic; and explosive (power actuated).
Several types of tools, such as saws, drills and grinders, are common to the first
three groups. Hydraulic tools are mainly for compression work. Explosive tools are
used exclusively for penetration work, cutting and compression.
Electrically Powered Tools
Electric drills
• Electric drills cause injuries in several ways. A part of the drill may be pushed
into the hand, the leg, or other parts of the body. Although no guards are
available for drill bits, some protection is afforded if drill bits are carefully
chosen for the work to be done. The operator should select drill bits
necessary to do the particular job;
• Oversized bits must not be ground down to fit a small drill.
Soldering irons
• Soldering irons should have insulated, noncombustible holders to prevent fire

or burns from accidental contact. Ordinary metal covering on wood tables is
not sufficient because heat conducted by the metal may ignite the wood.
• Harmful quantities of fumes from lead soldering must not be allowed to accumulate.
Exhaust may be necessary.
Air Powered Tools
Air hoses
• An air hose presents the same tripping or stumbling hazard as cords on

electric tools. Persons or materials accidentally hitting the hose may
unbalance the operator or cause the tool to fall from an overhead place;
• Air hoses should be protected from trucks and pedestrians by runways or
planks laid on either side of the hose;
• Do not disconnect an air hose from the tool being used, and use that air hose
for cleaning purposes;
• Air should be cut off before attempting to disconnect the air hose from the
line. Air pressure in the hose should also be cleared before disconnecting.
• Eye protection is required when operating air power tools. Safety-check
valves are recommended to automatically shut off air supply if a crack or
leak occurs.
Most pneumatic impact tools, such as jackhammers, are similar in that the proper
tool is fitted into the gun and receives its impact from a rapidly moving
reciprocating piston driven by compressed air at about 90 p.s.i. pressure.
- 87 -
• Noise levels from pneumatic tools should be measured to determine if
hearing protection devices for workers are necessary to comply with state
and federal standards.
• Never operate an air hammer until the tool is resting on the work surface.
Never point pneumatic equipment at other personnel;
• All workers in the vicinity of air hammer operations must wear eye protection
and, if necessary, protective clothing.
• Pneumatic impact tools should have an automatic closing value actuated by a
trigger located inside the handle
• A retaining device must hold the tool in place so that it cannot be fired
accidentally from the barrel;
• Jackhammer operators should wear safety shoes and jackhammers should
have heavy rubber grips to reduce operator fatigue.
Gasoline-Powered Tools
Gasoline-powered tools are widely used in construction, or other heavy industry.

Probably the best known, and most prevalent, is the chain saw.
Operators of gasoline-powered tools must be trained in their proper operation

according to the manufacturer's instructions.
Operators must be familiar with fuel hazards.
Explosive Actuated Tools
Supervisors should evaluate materials to be penetrated by explosive actuated tools.

They should ensure that correct size and strength of explosive charges and
thoroughly train employees using them.
These devices must be designed in accordance with American National Standards

Institute A-10.3.
Fasteners should not be driven into masonry closer than 3 inches to a corner or
edge unless jigs or special guards are used to stop flying particles. Fasteners should
not be fired into steel closer than 1/2 inch to an edge, corner or joint.
Proper eye protection must be worn during these operations.
These devices must never be activated in explosive or flammable atmospheres.
Tools and explosive charges must be stored in separate containers that are locked
or otherwise protected from use by unauthorized individuals.
- 88 -
Appendix 1: Checklist
The following checklist is intended to assist the reader in determining the degree of
compliance, within his/her operation, with the requirements of this procedure. Any
"no" answer should be cause for concern and correction action.
General Requirements Yes No

Power Controls
Are all hand held powered tools equipped with a positive on-off control,
such as:
A constant pressure switch or control ("dead man's
switch") which will shut off the power when the
pressure is released?
A constant pressure throttle which will shut off the
power when the pressure is released (i.e., gasoline
powered chain saws)?
A lock-on control which allows the power to be
discontinued by a single motion of the same finger
or fingers which turned it on?
Is the operating control on hand-held power tools
located so as to minimize the potential of its
accidental operation, if such accidental operation
presents a hazard to employees?
Safe Electrical Connections
Are employees required, before using portable
power tools, to inspect the wiring to ensure that it is
not broken, loose or frayed?
Are electrical hazards repaired immediately upon
identification?
If not, is the equipment deadlined until repairs can
be effected?
Are employees required to use only low voltage
power tools which are authorized for use in tanks or
wet areas, if such work is required?
Are explosion proof electrically powered tools
available for use in environments where flammable
gases, highly volatile liquids, and other explosive
substances are stored or used?
Are all electrical sources for power tools
continuously grounded?
If extension cords are necessary, is it ensured that
they are properly sized to the wattage of the tool?
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Do employees routinely report defects or minor
shocks to the supervisor? Does the supervisor
immediately effect repairs or deadline the defective
equipment?
Is the area constantly surveyed to ensure that
power cords do not become a tripping hazard, or
that operating equipment cannot be jerked from the
hands of the operator?
Guarding
Are all portable, power-driven saws with a blade
diameter greater than 2 inches equipped with
guards above and below the base plate of the shoe?
Are all portable abrasive wheels and portable
grinders permanently guarded on top, both sides,
and bottom of the wheel?
Are scratch brushes used on portable power tools
permanently guarded in the same manner as are
grinding wheels?
Are fastening tools actuated by explosive charges
guarded at the muzzle end?
Have all portable tools been inspected to ensure
that the operator and other employees are
protected with appropriate guarding from hazards
such as exposed belts, exposed rotating parts,
flying chips and sparks?
Have all tools without the appropriate guarding
been deadlined until guarding can be effected?
Is appropriate personal protective equipment
provided all operators and helpers, and its use
required, where tools may produce flying objects or
dust, in accordance with OP-G-1.1.2.3?
Has suitable hearing protection been provided and
its use required, in accordance with OP-G-1.1.2.3,
for jobs which may involve the risk of hearing loss?
Is the wearing of loose fitting clothing, long loose
hair or jewelry prohibited by employees working
with power tools with revolving parts?
Are safety shoes provided and their use required for
employees who use portable power tools of
significant weight which may injure the feet should
the tool fall or be dropped? (See OP-G-1.1.2.3.)
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If power tools are used in overhead places, is the
operator required to wear a safety belt or shoulder
harness to minimize the danger of falling, should
the tool break suddenly or shock the operator?
In accordance with OP-G-1.1.2.3, are suitable
respirators provided, their use required, and the
affected employees trained in such use, when
performing jobs where harmful dusts may be
produced, such as buffing, grinding, sanding or
mixing jobs?
Housekeeping
Are brushes or rags provided to clean metal slivers,
sawdust or other debris from machines? Are
employees instructed to never use bare hands for
this task?
Are employees trained to never attempt to clean a
machine which is turned on?
If compressed air is used for cleaning tools, is the
pressure 30 P.S.I or less?
If compressed air is used, is suitable eye protection
provided and it use required while tools are being
pressure cleaned?
Is there an approved metal container for the
storage of oily rags, wastes or other materials
saturated with combustible substances?
Are the containers emptied in an approved manner
on a daily basis?
Have approved exhausts been installed on machines
which may produce large amounts of dust?
Are safety zones, if required, clearly established and
marked?
Safety Procedures and Training
Have all operators of portable power tools been
thoroughly and tested in the safe operation of the
tools?
Have all manufacturer's manuals and diagrams on
file in the shop and available to employees
operating the tools for reference?
If these materials are not on hand, has the

supervisor contacted the manufacturers or worked
through Environmental Health and Safety to obtain
the necessary information to ensure safe operation
of the machines?
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Has the supervisor established procedures for the
care, inspection and safe use of all power tools in
the shop?
Does s/he insist that all employees follow the
procedures when using portable power tools?
Specific Recommendations for Safe Use of Portable Power Tools
Electrically Powered Tools
Are employees who may use electric drills trained to:
Carefully choose the correct drill for the job?
Never ground down an oversized bit to fit a small
drill?
Are employees who may use soldering irons trained to:
Ensure that soldering irons have insulated,
noncombustible holders, and to never place the hot
iron down on tables or workbenches?
Appropriately exhaust the area, in accordance with
instructions in OP-G-1.1.2.3, should they be
soldering lead that may create harmful quantities of
fumes?
Are employees who may use air hoses trained to:
Remember that the air hoses present a tripping
hazard, to make every effort to warn co-workers of
the location of the hose or otherwise minimize its
potential to cause falls or unbalance materials?
Place planks on either side of the hose to protect it
from vehicle and pedestrian traffic?
Never disconnect the air hose from the tool being
used in order to use the hose for cleaning purposes?
To turn off air prior to attempting to disconnect the
hose from the line, and clear the air pressure from
the hose before disconnecting?
To use eye protection at all times when using the air
hose in accordance with OP-G-1.1.2.3?
Ensure the safety-check valve is operating to
automatically shut off air supply should a crack or
leak occur?
Are pneumatic impact tool operators trained to:
Have the noise levels from the pneumatic tools
measured by Environmental Health and Safety to
ensure that appropriate hearing protection is
provided and used in accordance with standards set
forth in OP-G-1.1.2.3?
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Never operate an air hammer until the tool is
resting on the work surface?
Never point pneumatic equipment at other people?
Ensure that all workers in the vicinity of air hammer
operations wear eye protection and, if necessary,
protective clothing in accordance with OP-G-
1.1.2.3?
Use pneumatic impact tools with an automatic
closing valve actuated by a trigger located inside
the handle where it is safe from accidental
operation?
Ensure that the machine has a retaining device to
hold the tool in place so that it cannot be fired
accidentally from the barrel?
Wear safety shoes when operating jackhammers
and ensure that the jackhammers have heavy
rubber grips to reduce operator fatigue?
Gasoline-Powered Tools
Are operators of chain saws trained using the
manufacturer's manual in the safe operation of the
chain saw?
Are operators of gasoline powered tools trained the
safe handling of fuel according to OP-G-1.8?
Torches
Please see the checklist for OP-G-1.8.
Explosive Actuated Tools
Does the supervisor evaluate materials to be
penetrated by explosive actuated tools to ensure
that the correct size and strength of explosive
charges is implemented?
Are employees thoroughly trained by the supervisor

on this equipment prior to their using it?
Are all explosive devices designed in accordance
with American National Standards Institute A-10.3?
Are employees trained that fasteners should not be
driven into masonry closer than 3 inches from a
corner or edge unless jigs or special guards are
used to stop flying particles?
Are they trained that fasteners should not be fired
into steel closer than 1/2 inch from an edge, corner
or joint?
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Is appropriate eye protection provided and its use
required in accordance with OP-G-1.1.2.3?
Is the activation of these devices prohibited in
explosive or flammable atmospheres?
Are tools and explosive charges stored in separate
containers which are locked or otherwise protected
from use by an unauthorized individual?
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Armored & Metal Clad – From www.afcweb.com
Below are some of the most commonly asked questions by

AFC customers.
What is the difference between AC and MC Cables?
One of the most important differences between these two

cable types is the grounding means of the assembly.
Type AC cable uses the interior bond wire in combination

with the exterior interlocked metal armor as the equipment
grounding means of the cable.
Type MC cable is manufactured with a green insulated

grounding conductor, and this conductor, in combination
with the metallic armor, comprises the equipment ground.
See the Grounding Capabilities Chart.
Other differences:
AC cable may have up to 4 insulated conductors only; a fifth

insulated conductor is allowed by U.L. if it is a grounding
conductor. Each conductor in Type AC cable is paper
wrapped. Type MC cable has an overall Mylar wrap
enclosing the conductors.
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NEC Article 333 covers armored cables. Armored cables are
manufactured in accordance with U.L. 4.
NEC Article 334 covers metal clad cables. MC cables are

manufactured in accordance with U.L. 1569.
Only MC cables may be used in places of assembly over 100

persons, per NEC Article 518. HCF Type AC cable may be
used in health care facilities, per NEC Article 517.
What's the difference between HCF and MC cable?
The difference between HCF and MC cables (as

manufactured by AFC Cable Systems) is the grounding
capabilities of the cable assemblies.
Type HCF cable has a green grounding conductor plus the

armor/bond wire combination, thereby providing redundant
or isolated grounding capability. HCF is a Type AC cable
and is manufactured in accordance with U.L. 4.
HCF cable may be installed in compliance with NEC 517 for

health care facilities.
Type MC has only one equipment grounding means, a green

grounding conductor. There are types of MC cable
manufactured by AFC with two grounding conductors for
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additional grounding capability.
Where do I terminate that bare bond wire?
The bare wire in Type AC cables is a bonding wire to

enhance the ground fault capability of the interlocked outer
metal armor. It does not have to be terminated like a bare
grounding conductor because that is not its function. This
bare bond wire may be trimmed off to the same length as the
armor, or, brought up and over the red anti-short bushing and
back wrapped over the armor.
Why can't I use aluminum armored Type AC cables

on a DC circuit?
U.L. has not approved aluminum armored Type AC cable for

use on DC circuits. During the extreme testing procedures
conducted by U.L., a conductor was energized to arc and
caused the aluminum to burn. Normal usage would be 12DC
or 24DC, but U.L. has not tested the cable under those
conditions. Steel armored Type MC cable may be used on
DC Circuits without exception.
For answers to questions not listed here,

or for further explanation,
contact AFC Technical Services at 800-757-6996.
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Cords
In the picture above, The AWG 12-3 is telling you the American Wire Gauge (AWG) is 12
and there are 3 wires inside.
Insulation types
O: Oil-resistant, usually synthetic-rubber jacket, more flexible in cold temperatures

OO: Oil-resistant synthetic-rubber jacket and inner-conductor insulation
S: Standard service (synthetic-rubber insulated, rated for 600v)
SE: Extra-hard usage, elastomer
SEOW: Oil-resistant and weather-resistant elastomer jacket, rated for 600v (photo above)
SJ: Service junior (synthetic-rubber insulated, rated for 300v)
SJO: Same as SJ but Neoprene, oil resist compound outer jacket, rated for 300v
SJOW: Oil-resistant and weather-resistant synthetic rubber, rated for 300v
SJOOW: Oil-resistant and weather-resistant synthetic rubber (jacket and conductor
insulation), rated for 300v
SJT: Hard service thermoplastic pr rubber insulate conductors with overall plastic jacket,
rated for 300v
SJTOW: Oil-resistant and weather-resistant thermoplastic, rated for 300v
SJTW: Thermoplastic-jacketed, weather-resistant, rated for 300v
SO: Extra hard service cord with oil resistant rubber jacket, 600v
SOOW: Same as SOW but with oil resistant rubber conductor insulation and suitable for
outdoor use.
SOW: Rubber jacketed portable cord with oil and water resistant outer jacket
SPT-1: All rubber, parallel-jacketed, two-conductor light duty cord for pendant or portable
use, rated for 300v
SPT-2: Same as SPT-1, but heavier construction, with or without third conductor for
grounding purposes, rated for 300v
SPT-3: Same as SPT-2, but heavier construction for refrigerators or room air conditioners,
rated for 300v
ST: Extra-hard usage, thermoplastic (PVC), 600v
STO: Same as ST but with oil resistant and thermoplastic outer jacket, 600v
STOW: Same as STO but with oil and water resistant thermoplastic outer jacket, 600v
SV: Vacuum cleaner cord, two or three conductor, rubber insulated, rubber jacket, 300v
SVO: Same as SV except neoprene jacket, 300v
SVT: Same as SV except all thermoplastic construction, 300v
SVTO: Same as SVT except with oil resistant jacket, 300v
THHN: 600v nylon jacketed building wire
THW: Thermoplastic vinyl insulated building wire, moisture and heat resistant
THWN: Same as THW but with nylon jacket
W: Extra-hard usage, weather-resistant
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AUTOMATION DIRECT – Direct seller of automation and industrial control products
Article extracted from www.automationdirect.com
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GRAINGER – Industrial Supplier - www.grainger.com
From the on-line CATALOG No 399 (PDF)
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Lamps HID – General Information
All-metal halide lamps, except I- reactor type meeting current not intended for use in the nited
Line, will start at ambient ANSI H37 ballast specs. States, due to potential shock
temperatures of -22°F (-30°C) Do not use either with CW (lead- hazard.
when used on ballasts meeting type) or CWA ballasts.
these specifications. Halarc® Lucalox Export Base Lamps
MXR32 lamps will start at
ambient temperatures of -22°F Note: Export Only lamps have a Caution Notice - Metal Halide
(-30°C). I-Line non-domestic (U.S.) base and Lamps
Multi-Vapor® will start at are not intended for use in the
ambient temperatures of 5°F United States, due to potential The following operating
(-15°C) when used on approved shock hazard. instructions must be complied
mercury ballasts. with to help avoid possible
Halarc® Operating Notes - shattering and early failure of the
Start Characteristics Electronic Ballasts lamp. Metal halide lamps are
constructed of an outer bulb with
Full light output does not occur The 32W Halarc lamps must be an internal arc tube made of
immediately when power is operated on special GE quartz. The arc tube operates
applied. Instead, there is a time Lighting-approved ballasts. A under high pressure at very high
delay for the lamp to reach suitable high power factor temperatures— as high as
90% total light output. The electronic ballast is Hal 32/120 approximately 1100°C.
starting delay for Lucalox® is 3 for 120V applications. The The arc tube and outer bulb may
to 4 minutes, for Multi-Vapor 2 to outside dimensions are 9.25" unexpectedly rupture due to
5 minutes, and for mercury 5 to (235mm) long, 3.125" (78mm) internal causes or external
7 minutes. wide and 1.75" (45mm) high. factors such as a system failure
or misapplication.
Restart Characteristics I-Line Multi-Vapor Lamps —Lamp may only be operated in
Operating Position the types of fixtures prescribed
With a power interruption of one in the applicable specification
half cycle or more, the arc will Universal—U: Burn any position, bulletin. Fixture lens/diffuser
extinguish. When power is but in positions other than material must be able to contain
immediately reapplied, full light vertical base up or base down, fragments of hot quartz or glass
output does not occur use only in enclosed fixtures (up to 1100°C). If in doubt,
immediately. For HPS lamps which can contain fragments of contact your fixture
there is a delay of 1 minute to hot quartz or glass. manufacturer.
reach 90% total light output; Vertical VBU/VBD: Vertical base —Electrically insulate any metal-
however, the Lucalox® LU1000 up or vertical base down lamp to-glass support in fixture to
requires 2 minutes and the must be operated only within 15° avoid decomposition of the
E-Z Lux® lamps require 3 of vertical. glass.
minutes to reach 90% total light —Protect lamp from direct
output. For Multi-Vapor lamps, Arcstream™ Metal Halide contact with liquids (such as
when the power is immediately Lamps - Operating Notes water) to avoid breakage from
reapplied, there will be a delay of thermal shock.
15 to 20 minutes before the It is important that tubular —In continuously operating
lamps reach the 90% light output shaped lamps are operated in systems (24 hours/day, 7
level. The restart delay for suitably enclosed luminaires with days/week), turn lamps off once
mercury lamps is 3 to 6 minutes a UV-absorbing cover glass. Full per week for at least 15 min.
to reach 90% total light output. enclosure will also retain any Failure to comply increases risk
fragments of quartz in the of rupture. Not required for
E-Z Lux® Lucalox® Lamps unusual event of the outer bulb ceramic metal halide lamps.
Operating Notes shattering. All Arcstream lamps —Screw lamp firmly but not
can operate on the relevant forcibly into the socket to
Use 150W E-Z Lux only with double-ended metal halide minimize loosening due to
H39 175W mercury ballasts: ballasts. vibration. Do not use excessive
high reactance lag-type auto force as the glass bulb may
transformer, 240V or 277V Multi-Vapor Export Base break.
reactor. Use 215W E-Z Lux only Lamps Wattage Range: 32 to —Do not scratch glass bulb
with H37 250W mercury ballasts: 1000W because it may break during
high reactance lag-type auto installation or later during lamp
transformer, 240V or 277V Export Only lamps have a non- operation.
domestic (U.S.) base and are
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—Relamp fixtures at or before "MBI150PAR64..."), and all unexpectedly rupture due to
the end of rated life. Beyond standard mercury lamps (those internal causes or external
rated life, light output diminishes having lamp designations factors such as a system failure
while energy consumption and beginning with the letters or misapplication.
risk of rupture increase. "HR..."): "WARNING. This lamp —Lamp may be operated in any
—Turn power off and let lamp can cause serious skin burn position. Lamp must only be
cool before removal to avoid and eye inflammation from operated with compatible
potential burn and electrical shortwave ultraviolet radiation electrical equipment in the types
shock hazard during lamp if outer envelope of the lamp of fixtures prescribed in the
replacement. is broken or punctured and applicable specification bulletin.
—Use In Enclosed Fixtures. For the arc tube continues to Fixture lens/diffuser material
lamps requiring enclosed operate. Do not use where must be able to contain
fixtures, fixture lens/diffuser people will remain for more fragments of hot quartz or glass
material must be able to contain than a few minutes unless (up to 1100°C). If in doubt,
fragments of hot quartz or glass adequate shielding or other contact your fixture
(up to 1100°C). safety precautions are used. manufacturer.
—Use In Open Fixtures. For Certain types of lamps that —Electrically insulate any metal-
lamps operated in the vertical will automatically extinguish to-glass support in fixture to
position that are not designated when the outer envelope is avoid decomposition of the
"Enclosed Fixtures Only," lamp broken or punctured are glass.
may be used in an open or commercially available from —Protect lamps from direct
enclosed lighting fixture General Electric Company. contact with liquids (rain, sleet,
depending upon the application These are the self- or snow) to avoid breakage from
and operating environment. extinguishing Saf-T-Gard thermal shock.
For example, if the lamp is Mercury and Multi-Vapor —Screw lamp firmly but not
located near combustible lamps." forcibly into the socket to
material or in an area that is minimize loosening due to
unoccupied for extended Mercury Export Base Lamps vibration. Do not use excessive
periods, an enclosed fixture Wattage Range: 250W to force as the glass bulb may
which can contain fragments of 1000W break.
hot quartz or glass is —Do not scratch glass bulb
recommended. Export Only lamps have a non- because it may break during
Arcstream tubular lamps must domestic (U.S.) base and are installation or later during lamp
be used in enclosed fixtures with not intended for use in the operation.
UV-absorbing glass. Enclosed United States, due to potential —Turn power off and let lamp
fixtures must be capable shock hazard. cool before removal to avoid
of containing fragments of hot potential burn and electrical
quartz or glass (up to 1100°C). Caution Notice - Mercury shock hazard during lamp
Lamps replacement.
Important Notice —Relamp fixtures at or before
Mercury lamps are constructed the end of rated life. Beyond
In accordance with Federal of an outer bulb-with an internal rated life, light output diminishes
Standard 21 CFR 1040.30, the arc tube made of quartz. The arc while energy consumption and
following notice applies to the tube operates under high risk of rupture increase.
Multi-Vapor, Halarc, Arcstream pressure at very high
PAR 64 (those having lamp temperatures— as high as
designations beginning with the approximately 1100°C. The arc
letters "MVR...," "MXR..." or tube and outer bulb may
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Consumer Product Safety Commission
Preventing Home Fires: Arc Fault Circuit Interrupters (AFCIs)
Problems in home wiring, like arcing and sparking, are associated with more than 40,000 home fires
each year. These fires claim over 350 lives and injure 1,400 victims annually.
A new electrical safety device for homes, called an arc fault circuit interrupter or AFCI, is expected to provide
enhanced protection from fires resulting from these unsafe home wiring conditions.
Typical household fuses and circuit breakers do not respond to early arcing and sparking conditions in home
wiring. By the time a fuse or circuit breaker opens a circuit to defuse these conditions, a fire may already have
begun.
Several years ago, a CPSC study identified arc fault detection as a promising new technology. Since then,
CPSC electrical engineers have tested the new AFCIs on the market and found these products to be
effective.
Requiring AFCIs
AFCIs are already recognized for their effectiveness in preventing fires. The most recent edition of the
National Electrical Code, the widely-adopted model code for electrical wiring, will require AFCIs for bedroom
circuits in new residential construction, effective January 2002.
Future editions of the code, which is updated every three years, could expand coverage.
AFCIs vs. GFCIs
AFCIs should not be confused with ground fault circuit interrupters or GFCIs. The popular GFCI devices are
designed to provide protection from the serious consequences of electric shock.
While both AFCIs and GFCIs are important safety devices, they have different functions. AFCIs are intended
to address fire hazards; GFCIs address shock hazards. Combination devices that include both AFCI and
GFCI protection in one unit will become available soon.
AFCIs can be installed in any 15 or 20-ampere branch circuit in homes today and are currently available as
circuit breakers with built-in AFCI features. In the near future, other types of devices with AFCI protection will
be available.
Should You Install AFCIs?
You may want to consider adding AFCI protection for both new and existing homes. Older homes with
ordinary circuit breakers especially may benefit from the added protection against the arcing faults that can
occur in aging wiring systems.
For more information about AFCIs, contact an electrical supply store, an electrician, or the manufacturer of
the circuit breakers already installed in your home. Sometimes these components can be replaced with AFCIs
in the existing electrical panel box.
Be sure to have a qualified electrician install AFCIs; do not attempt this work yourself. The installation involves
working within electrical panel boxes that are usually electrically live, even with the main circuit breakers turned off.
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Underwriters Laboratories Inc
Arc-Fault Circuit Interrupters (AFCIs) - Type and Performance Considerations
Read the full article at www.ul.com/regulators/afci/Dini2.pdf
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Other Transformer Products
Control Power Transformers
Application • Secondary fuse protection kits — are available for 25-

Square D manufactures three lines of general purpose control 750 VA standard and 50-1000 VA for high efficiency. Indi-
power transformers, a high-efficiency line, a standard line, and cated as type S if factory installed or AP if field installed.
an international line. All three lines are specifically designed to • Shorting bars — for interconnnecting terminals of dual-
handle high inrush associated with contactors and relays for voltage transformers are included, extras available in sepa-
applications such as conveyor systems, paint lines, punch rate kits. Indicated as type SB.
presses, or overhead cranes. • Special sizes and voltage combinations are available.
Type T and TF control power transformers, designed for interna- • Transformer kits — for factory or field installation in combi-
tional markets, are rated for 50/60 Hz. They are the best choice nation starters. Indicated as type GO or GFT.
when size and cost are of concern for 50-1000 VA and when Enhancements for Type T and TF Line Only
products need to meet the CE mark for international standards. • Fingersafe® Covers — snap on to meet CE requirements
The Type T, like the Type K, also offers various temperature (FSC-1 50-200 VA, FSC-2 250-1000 VA, and FSC-23 spe-
classes: cial 6 terminal applications)
• 50-150 VA with a 55°C Temperature Rise • Fuse Pullers Kit — offers finger protection from fuse block
• 200-350 VA with a 80°C Temperature Rise for CE requirements and facilitates every fuse change out.
• 500-1000 VA with a 115°C Temperature Rise (FP-1)
• Secondary Fuse Protection Kits — now available field-
Separate Fingersafe® accessory kits may be purchased and installable. Indicated as SF type.
installed to meet EN60-742 for CE approval. The Type T and TF
line meets requirements of UL, CSA, CE, and NOM. They are Regulation
UL Listed under E61239, Guide XPTQ2, CSA certified under Class 9070 transformers are designed with low impedance wind-
LR37055, Guide 184-N-90, CE marked under EN60742, and ings for excellence voltage regulation. This allows Class 9070
NOM117. transformers to accommodate the high momentary inrush cur-
rent caused when electromechanical devices such as contac-
The standard line, Type K (1000-5000 VA) transformers, are the
tors, relays and solenoids are energized. The secondary voltage
best choice if size and cost are of concern. These standard
drop between no load and momentary overload is low, helping to
units use the most advanced insulating materials, making it
assure satisfactory operation of magnetic components.
possible to offer the advantages of different temperature
classes: Selection Guide
1. Determine inrush and sealed VA of each coil in the control
• 50 VA- 250 VA with a 55˚C Temperature Rise
circuit.
• 300 VA- 350 VA with a 80˚C Temperature Rise
2. Total the sealed VA of all coils.
• 500 VA - 5000 VA with a 115˚C Temperature Rise
3. Total the inrush VA of all coils at 100% secondary voltage.
Type K control transformers are UL Listed under UL File Add this value to the total sealed VA present (if any) when
No.E61239, Guide XPTQ2 and CSA certified under CSA File inrush occurs.
No. LR37055, Guide 184–N–90. The standard line includes 4. If the supply voltage is stable and varies no more than ±5%,
Type KF designed with a top-mounted fuse block to accommo- refer to the 90% secondary voltage column. If the voltage
date two primary Class CC time delay fuses and one second- varies as much as ±10%, use the 95% voltage column.
ary 1.5" x 13/32" size fuse. 5. Using the regulation chart, select a transformer:
Type E control transformers are high-efficiency units with a A. With a continuous VA rating equal to or greater than the
55˚C temperature rise. This is the best choice when low heat value obtained in step 2
contribution is required. These high-efficiency units provide B. With a maximum inrush VA equal to or greater than the
extra regulation and lower energy losses. Type E control trans- value obtained in step 3
formers are UL listed under File E61239 and also CSA certified Regulation Chart — Inrush VA@ 30% Power Factor
under File No.LR37055, Guide 184–N–90. 95% Secondary 90% Secondary 85% Secondary
Voltage Voltage Voltage
All Square D control transformers are copper-wound, vacuum VA
Type Type Type T
impregnated with varnish and fully tested in strict compliance Type E Type K Type T Type E Type K Type T
E K
with ANSI, CSA, and UL codes. Windings are additive polarity. 25 72 N/A 161 109 N/A 221 131 N/A 281
50 171 161 161 235 221 221 299 281 281
Jumper cables are supplied with each transformer. 75 327 244 244 390 337 337 554 437 437
100 382 307 307 553 440 440 722 575 575
Enhancements for Special Applications 150 468 521 521 735 765 765 997 1014 1014
200 1065 1065 759 1538 1538 1060 2163 2163 1369
The standard, high-efficiency, and international models all have 250 1290 1290 1190 1949 1949 1660 2680 2680 2120
300 1700 1237 1335 2489 1775 1845 3384 2299 2350
designs adapted to meet the needs of special applications: 350 2500 1480 1610 4115 2104 2270 5393 2712 2910
500 3600 1836 2650 4836 2651 3500 6900 3441 4340
• Top-mounted fuse block —indicated as type KF, TF, or 750 6250 3482 3270 8583 5042 4895 13183 6564 6530
EOF. 1000 8750 4244 5350 13275 6345 7675 19462 8388 9935
1500 16500 10023 N/A 22863 14735 N/A 35378 19304 N/A
• Leads — instead of terminal boards, are available on lim- 2000 24300 12744 N/A 36688 19202 N/A 54737 25450 N/A
3000 28900 18176 N/A 44789 28096 N/A 98007 37797 N/A
ited sizes. Indicated as type KL or EL. 5000 78500 29868 N/A 116406 48349 N/A 187579 66541 N/A
29
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Extracts from –
Photovoltaic Power Systems and the National Electrical Code –
Suggested Practices; John Wiles; Southwest Technology Development
Institute; New Mexico State University
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From “JOINT DEPARTMENTS OF THE ARMY, THE NAVY AND THE AIR
FORCE, TM 5-864/NAVFAC MO-200/AFJMAN 32-1082
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GRAINGER – Industrial Supplier - www.grainger.com
From the on-line CATALOG No 399 (PDF)
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From “JOINT DEPARTMENTS OF THE ARMY, THE NAVY AND THE AIR
FORCE, TM 5-683/NAVFAC MO-116/AFJMAN 32-1083
Excerpts from Chapter 4 – Electrical motors maintenance
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NEW POOL SAFETY
SENATE BILL 873 POOL SAFETY: This new law requires that underwater light fixtures in
existing swimming pools and spas be protected by ground-fault circuit interrupter (GFI), and all light
fixtures in public swimming pools have encapsulated terminals. The ground-fault circuit interrupter
is a device that de-energizes an electrical circuit when the current to ground increases, preventing
electrocution. The law also requires all public wading pools to upgrade plumbing at the main drain.
The upgrade would require a dual drain system which is hydraulically balanced to prevent physical
entrapment or suction injury.
Who is affected by the law change?
A. Underwater lighting
The new law affects all public swimming pools and spas at motels, hotels, schools, health clubs,
public parks, mobile parks, apartments, private clubs, and condominiums with an underwater light of
15 volts or greater. The law also includes swimming pools and spas at multi-unit residential
dwellings (two or more units) with 15 volts or greater underwater lighting.
B. Main drain upgrade
The new law affects public wading pools only, Wading pool is defined by State Law as a pool used
for wading by small children and having a maximum depth not to exceed 18 inches.
When is the compliance date for these new laws?
A. Underwater lights
All pool and spa lights must be retrofitted with a ground-fault circuit interrupter and encapsulated
terminals by July 1, 1998. All work must be done by a licensed electrical contractor with a C-10
license or a swimming pool contractor with a C-53 license. All work must be inspected by a
representative of the city or county building department to ensure compliance by September 1,
1998.
B. Dual main drain upgrade for wading pools
All existing wading pools must be retrofitted to have at least two circulation drains by January
1, 2000. The drains shall be at least 3 feet apart and hydraulically balanced. If your wading pool is
remodeled or altered prior January 1, 2000 the pool must be retrofitted at that time.
How do I comply with the new law?
A. Pool lighting: Have your pool/spa lighting inspected by a licensed electrical contractor or a
swimming pool contractor to determine if it has a ground-fault circuit interrupter and that the
terminals in the light fixtures have approved encapsulations (NEC article 680-20 b, 1). If it does not
have a GFI circuit or approved encapsulation of terminals, take the following syeps:
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1. Contact a licensed electrician C-10 or swimming pool contractor C-53 to perform the work.
2. Contact your local building department to obtain the required building permit.
3. Contact local building department to have the work inspected and certified.
4. Make a copy of the building permit and send it to this office.
What if my pool light fixture already has an approved GFI circuit and proper terminal
encapsulation?
1. Have a licensed electrical contractor or swimming pool contractor complete and sign enclosed
form.
Wadding pool main drain upgrade:
1. Contact a pool contractor to do the work.
2. The pool contractor must submit constructions plans to our office for review and approval.
3. Obtain necessary permits from local building department.
4. Contact this office when the work is completed for inspection.
BUILDING DEPARTMENTS
CERES 538-5753
MODESTO 577-5232
NEWMAN 862-1506
OAKDALE 847-4245
PATTERSON 892-2041
STANISLAUS CO. 525-6557
RIVERBANK 869-7120
TURLOCK 668-5560
WATERFORD 874-2328
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What if I do not have an under water light? Or light does not work?
If your pool/spa does not have an underwater light fixture, the law does not apply to you. If you have
a light fixture and it does not work, the light must be repaired, or removed and plastered over.
Swimming pools and spas without lighting cannot be used after dusk. Signs must be posted
prohibiting the use of the pool/spa after sunset. The gates must be locked preventing entry.
THE RECREATIONAL HEALTH PROGRAM
It is our goal to use education as the major tool to achieve a successful recreational health program in
Stanislaus County. As our inspections are performed, we attempt to explain the reasons behind any
request for change.
We also have educational pamphlets and a video that are available for your use.
If you have any questions, or would like further information on educational

materials or training, please contact this office at 525-6700 or e-mail
[email protected]
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Basic Electronic Troubleshooting Techniques
Aug 1, 2004 12:00 PM, By John Olobri, AEMC Instruments
You can troubleshoot problems with electronic equipment by using a

few basic test instruments and a little common sense
As an industrial electrician, you'll encounter many complex electrical circuits and drives that will
break down as they age. Chances are, you won't be an expert in repairing these devices, but you can
take some practical steps to solve problems and help get your systems operational again in a timely
manner. Let's start with the motor drive.
Solid-state electronic AC motor drives are becoming more common within industrial plants. They
control a wide variety of devices like pumps, conveyors, air handlers, chillers, machine tools,
mixers, and a host of other devices once designed to run at constant speed or be powered by DC.
Since failure in these devices can be often attributed to the rectifier section, you'll need a
fundamental understanding of transistors, diodes, silicone controlled rectifiers (SCRs), and insulated
gate bipolar transistors (IGBTs).
Pulse width modulated (PWM) inverter drives are the most prevalent type of AC drives (Fig. 1
here). The AC line voltage is converted to DC (in the converter section) and then reconstructed back
into a variable frequency and a variable voltage output. Changing the frequency varies motor speed,
and motor torque is maintained by keeping the ratio of volts-to-frequency at a constant.
Troubleshooting variables frequency drive

isn't difficult, but it requires a methodical
approach.
Troubleshooting motor drives. Because most failures

occur within the power sections instead of the circuit
boards, they aren't very difficult to troubleshoot. The
typical plant maintenance technician will rarely see
enough failures to build up any proficiency in repairing
circuit boards.
Effective troubleshooting on a variable frequency drive

(VFD) requires a methodical approach. The classic
divide-and-conquer method, taught by most technical
schools, is effective when knowledge of the equipment
is limited. A good troubleshooter will first isolate the
box or section that isn't passing the signal and then
work on it.
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So how can you quickly and efficiently troubleshoot a dead VFD? Remember to always put safety
first. The capacitors within the power section can maintain a dangerous charge even after the power
is removed.
First make sure that the capacitors are discharged before putting your hands into the power section.
With the power off, begin checking the power sections of the drive. Then, place your digital
multimeter (DMM) in the diode check mode. Find the positive DC bus (sometimes this may be
brought out to a terminal), place the negative (black) lead from your DMM on it, and then check
each incoming phase in turn with the positive (red) lead. You should read a diode drop of about 0.6V
on each phase. If it reads open, then the charge resistor is open and needs to be replaced. This is a
common source of many problems.
Next, place the DMM's positive lead on the negative bus and the negative lead on each incoming
phase in turn as you did before. You should read a diode drop, not a short or an open. Place one
DMM input lead on the positive bus and the other on the negative bus. On this measurement you
should read the capacitor charging rather than a short.
To check the inverter section, place the positive DMM lead on the negative bus and the negative lead
on each output phase. You should read a diode drop because diodes are connected across each output
transistor. Again, you shouldn't read a short. Check the remainder of the inverter section by placing
the negative lead of the DMM on the positive bus, checking each output phase again with the
positive lead of the DMM. You should read a diode drop again and not a short. If you read OPEN
from either of these checks then the bus fuse is most likely open. If no problems are present within
the power section and the unit still won't function, it's either improperly connected or programmed or
has a bad circuit board.
Fig. 2. Thanks to IGBTs like this one,

newer PWMs are much less likely to
fail.
Newer PWM drives use IGBTs in the driver sections of the output, and are much less likely to fail.
These devices perform like a metal-oxide semiconductor field effect transistor (MOSFET). When
the voltage at the gate exceeds the threshold voltage, the device turns on. If the voltage applied to the
gate contact is less than the threshold voltage Vth, then the device is turned off (Fig. 2).
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Visual PLC troubleshooting techniques. Most PLCs incorporate light emitting diodes (LEDs) in
their design, which offer a good source of diagnostics. They can provide valuable information about
the wiring, and input/output (I/O) modules within the unit. Typically, I/O modules have at least one
LED indicator; input modules normally have a power indicator, while output modules usually have a
logic indicator.
A lit power LED on an input module indicates that the input device is operating and its signal is
present at the module. However, this indicator by itself can't isolate malfunctions to the module.
Consequently, some manufacturers provide an additional diagnostic indicator known as a logic
indicator. If a logic LED is lit, the logic section of the input circuit has recognized the presence of
the input signal. If the logic and power indicators don't match, then the module is unable to correctly
transfer the incoming signals to the processor. This indicates a module malfunction and most likely
points to the problem area.
The output module's indicator functions in a similar fashion to the input module's indicators. When
on, the logic LED indicates that the module's circuitry has acknowledged a command from the
processor to turn on. In addition to the logic indicator, some output modules incorporate either a fuse
indicator or a power indicator, or sometimes both. A blown fuse indicator displays the status of the
protective fuse in the output circuit. The power indicator displays that power is being applied to the
load. Similar to the power and logic indicators in the input module, if both LEDs aren't on
simultaneously, the output module is malfunctioning — again pointing to the probable problem area.
As you can see, LED indicators greatly assist the troubleshooting process. With power and logic
indicators, you can immediately pinpoint a malfunctioning module or circuit. Although they can't
diagnose all problems, they serve as a good first round indicator of a system malfunction.
Troubleshooting the PLC inputs. If the field device connected to an input module doesn't seem to
turn on, a problem may exist somewhere between the line connection and the terminal connection to
the module.
First place the PLC in standby mode so the output isn't activated. This will permit you to manually
activate the field device. A limit switch can usually be manually closed to achieve this result. When
the field device is manually activated, the module's power status indicator should turn on, indicating
the power link is working properly. If this occurs, then the wiring most likely isn't the root of the
problem.
Next, analyze the reading of the PLC's input module. Place the PLC in its test mode. The device
should read its inputs and execute its program, but not turn on its outputs. If the PLC reads the
device correctly, then you know the problem isn't located in the input module. If it doesn't read the
device correctly, then the module could be defective. However, several causes are possible. First, the
logic side of the module may not be operating correctly. Second, its optical isolator may be blown.
Third, one of the module's interfacing channels could be damaged. In any case, you'll need to replace
the module.
If the module doesn't read the field device's signal, then further tests are required. Bad wiring, a
faulty field device, a faulty module, or an improper voltage between the field device and the module
could be causing the problem. First, measure the voltage to the AC input module. Your DMM
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should be in voltage measuring mode and should display the voltage that powers the module. If the
voltage is present and at the correct level, you know you have a bad input module because it's not
recognizing the applied voltage. If the measured voltage is 10% to 15% below the specified signal
voltage, then the problem most likely is in the source voltage to the field device. If no voltage is
present, then the wiring is broken or shorted or the field device is dragging it down. Check the
wiring connection to the module to ensure that the wire is properly secured at the terminal or
terminal blocks. You can also perform an insulation check on the wiring to look for shorts and/or
damaged insulation. Be sure that the system is de-energized first before conducting this test.
To further locate the problem, confirm that voltage is present at the field unit. With the device turned
on, measure the voltage across it using your DMM. If no voltage is present on the load side of the
unit (the side that connects to the module), then the input device is probably defective. If there is
power, then the problem is in the wiring from the input device to the module. In this case, the wiring
must be inspected and tested to find the problem.
Troubleshooting PLC outputs. The first step in troubleshooting the outputs is to isolate the
problem to either the module, the field device, or the wiring.
First check that the source of power to the output module is at the specified level. This value should
be within 10% of the rated value. In a 120VAC system, for example, it should be between 108VAC
and 132VAC. Examine the output module. If the fuse is blown, check its rated value to be sure the
correct fuse was installed in the first place. Also, check the output device's current specifications to
determine if the device is pulling too much current.
If the module's output status indicator fails to turn on despite receiving the instruction to turn on
from the central processing unit, it's faulty. If the indicator does turn on and the field device doesn't
activate, then check for voltage at the output terminal to be sure that the switching device is, in fact,
operational. If no voltage is present, then you should replace the module. If voltage is present, then
the problem lies in the wiring or the field device. At this point, make sure the field wiring to the
module's terminal or to the terminal block has a good connection and that no wires are broken. This
can be accomplished in the same fashion as described earlier.
When you finish checking the output module, check to see that the field device is functioning
correctly. Check the voltage coming to the field device while the output module is on. If voltage is
present, but the device doesn't respond, then the field device is probably defective or damaged.
One trick for checking the field device is to test it without using the output module. Remove the
output wiring and connect the field device directly to the power source. If the field device doesn't
respond, then it's faulty. If the field device responds, then the problem lies in the wiring between the
device and the output module. Check the wiring, as noted earlier, looking for broken wires, shorts,
worn insulation, and oil or grease on the connection points and along the wiring route.
Troubleshooting the CPU. PLCs also provide diagnostic indicators that show the status of the
central processing unit (CPU). These indicators include such display messages as POWER OK,
MEMORY OK, and COMMUNICATIONS OK.
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You should first check that the PLC is receiving enough power from the transformer to supply all the
loads. If the power received is in accordance with specifications and the PLC still isn't working,
check for a voltage drop in the control circuit or for blown fuses. If these conditions are all proper,
then the problem lies in the CPU. Most likely, the diagnostic indicators on the front of the CPU will
display a fault in either memory or communications mode. Should one of these indicators be lit, it's
highly likely that the CPU needs to be replaced.
Troubleshooting the input and output sections of a motor drive can be easy when approached
logically and addressed section by section. All you need to do is measure volts and ohms with a
DMM. As with motor drives, the most practical method you can use to diagnose PLC input/output
malfunctions is to isolate the problem to either the wiring, the module, or the field device. When
these systems have both power and logic indicators for you to view and interpret, then module
failures become very easy to recognize and isolate.
Olobri is a product development manager for AEMC Instruments, Foxborough, Mass.
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LAB #1 – Bending with Hand Benders – EMT
Tool set - Provided
A ½” EMT hand bender

A pipe cutter or a hack saw
A reamer
A tape measure
A level, a protractor, and a square
Safety equipment required – provided
Safety goggles
Safety equipment recommended – No provided
Gloves
Working boots
Materials
10’ of ½” trade size EMT conduit
Before start, check schematics at the end of this lab
Task #1
Cut 4 pieces, 2’ 6” long (or as close as it is possible, since conduit sticks are not 120” long), of ½”
trade size EMT and ream the sharp internal edges.
The lengths of the pieces are:

Piece #1:
Piece #2:
Piece #3:
Piece #4:
Task #2
2.1 Using Pieces #1 and #2, bend two 8 3/8” stub
Knowing the original length of the pieces of conduits, calculate the GAIN of the ½” hand bender.
Having two stub-ups, average the gain value obtained from each case.
½” HB GAIN
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2.2 Kick the conduits to put the 90º 4” above bottom plane level. Conduits should meet end to
end
Task #3
Bend
Two 4” 45º offsets
Leave 4” from the end of the conduit to the first mark. Conduits must meet end to end
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LAB #2 – Bending with Mechanic Benders – IMC
Tool set - Provided
A Mechanic Bender
A tri-stand
A pipe cutter
A hack saw
A reamer
A threader w/ bucket, hand-pump and cutting oil
A tape measure
Safety goggles
Safety equipment [strongly] recommended – No provided
Gloves
Working boots
Materials: ONE ¾” trade size IMC stick
Chart the bender before proceed – Instructor will give guidance
Task #1 - Calculate the amount of conduit necessary to bend a 4’ back to back type “U”; the picture
shows the size of the stub-ups and the back to back distance, and proceed to make it.
26” 9 ½”
48”
Task #2
Bend Calculations
Using the rest of the conduit bend a 6” 45º offset.
BTB Lth 90M BM
BTB
M1 DBM
FST
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BENDER NOTES
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LAB #3 – EMT project
READ UNDERSTAND PLAN YOUR WORK WORK YOUR PLAN
Tool set - Provided
A Hand Bender
A pipe cutter or a hack saw
A reamer
A tape measure
A V-Ω-A meter
Safety goggles
Gloves
Working boots
Materials
A lab tray w\ a switch board and 3 boxes

Conduit – 1 stick of ½” EMT
Conductors – THW AWG #14 – Black, Red, White and Green
Receptacles – One double receptacle
Switches – Two 3 way and one duplex
Load – An “Edison” type bulb socket w/ a 60W incandescent bulb
OCPD – One 15A CB
Task #1
Connect the square box with the left side handy box,
using the bottom square box’s fitting –BACK to
BACK
Connect the square box with the right side handy box
using the mid square box’s fitting - 90º and a KICK
Connect the panel board with the square box using

the top square box’s fitting – OFFSET
Verify with your instructor if bends are acceptable.

Next some orientation about how to perform the
bends
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The Back-to-Back
1) Measure the distance between targets Back-to-Back + End-to-End, subtract 2 x GAIN, add
the small shrink the SHORT OFFSETS are going to produce – 1/8 altogether (1/16 each).
The result is the length of the conduit that is necessary.
2) CUT’n REAM
3) Produce a SHORT OFFSET at each end, being careful not to make a “twist” between them.
NOTE: This step CAN be made at the end of this procedure.
4) Mark from the square box end the size of the stub required – You will determine how much
is that STUB. BE CAREFUL, it can not be too short because the rectangular box will be in
the way, and cannot be too long because the offset to connect the load center with square box
will need some room.. DO NOT forget that stubs need DEDUCTS. This will be the 1st mark.
5) Carefully and with attention to details, perform the first 90º using the ARROW as reference.
6) From the stub back mark the BTB distance. This will be the 2nd mark.
7) Make a 90º at the 2nd mark– [WHATCH OUT the direction of your bend!!!] using the STAR
–remember that for the second bend you have to REVERSE the bender (in both ways, shoe
and handle since the BTB is a “S” and not an “U”)
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The “Kicked” 90º
1) Measure the distance between targets End to Back + Back to End, subtract GAIN, add 1”
to compensate the KICK’s SHRINK, and add 1/16” to compensate the SHORT OFFSET
shrink.
2) CUT’n REAM
3) Mark one end with the size of the desire STUB.

DO NOT forget that stubs need DEDUCTS
4) Make the 90º at the mark using the ARROW
5) With your partner produce the desire KICK as it

was done in Lab #1 - [WHATCH OUT the
direction of your bend!!!] – Do it as close as
possible of the 90º (bend radius)
Suggestion: Place the hook of your bender

immediately after the 90º end.
6) Once the kick is done, measure from the stub back

the distance to fitting and add 1/16 to compensate
the shrink of the short offset.
7) Mark and CUT the Leg’s excess, leaving the pipe 1/16 larger than what seems to be
necessary. Produce a SHORT OFFSET at the end of the LEG - [WHATCH OUT the
direction of your bend!!!]
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The “overpassing” OFFSET
The difficulty in performing this offset in the way it is required, resides in the fact that we will
determine the marks in the opposite way than we did in Lab #1 and #2. In those cases we assumed
that we were “jumping” to a higher level. In this case we work from the square box to the load center
what makes us go from a high level to a lower level. This is not the only solution to this problem. Of
course we can make this offset from the load center to the square box, but it is asked to solve the
offset in this fashion to experiment with the opposite situation presented in labs 1 and 2.
1) Measure the OFFSET rise.
2) Measure the distance between targets, End-to-End, and add SHRINK (based on the selected
angle) and 1/16” to compensate the SHORT OFFSET shrink.
3) CUT’n REAM
4) Measure the distance between the square box fitting’s end to the back of the further tube
and add the arc development plus DBM. This will be MARK 1.
5) Mark DBM back from M1 – MARK 2
6) Produce the SHORT OFFSET at the load center end.
NOTE: The final length of the tube will not allow you to perform SHORT OFFSET the after
the OFFSET is done
7) Bend the OFFSET [BEWARE THE DOG LEG!!!]
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Task #2
2.1 Run wiring for a split-wire receptacle and a single lighting outlet controlled from a duplex
switch - Draw a simple wiring diagram. Verify with instructor if wiring is acceptable
WITH your instructor
Test circuit and wires

(continuity and insulation)
Energize and try out your

circuit.
Perform a routine of
measurements in the circuit –
Voltages, currents.
2.2 Run wiring for a 3-way circuit - Draw a simple wiring diagram. Verify with instructor if
wiring is acceptable
WITH your instructor
Test circuit and wires (continuity

and insulation)
Energize and try out your

circuit.
Perform a routine of
measurements in the circuit –
Voltages, currents.
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LAB #4a – Control Circuits – 1st part
READ UNDERSTAND PLAN YOUR WORK WORK YOUR PLAN
Tool set - Provided
A 3/32 slotted screw driver

A V-Ω-A meter
Safety goggles
Working boots
Materials
A wood frame provided with a 10 spaces Cutler-Hammer Load Center w/two Cutler-
Hammer 15 Amps Circuit Breakers.
A 1/8 HP motor - single phase.
A Start-Stop station
A Motion Sensor.
An 8 Pins Relay.
A GE NEMA 1 Starter.
A 24-hours Cycle Timer.
A duplex fluorescent lamp fixture w/two 13W compact fluorescent lamps.
A bulb socket w/a 60W incandescent lamp.
Review of concepts – Ladder logic – transformers - protections
Read the guidelines bellow before proceed to wire the components
Connect two circuits to fulfill these conditions
A) The Cycle Timer has to turn ON the fluorescent fixture (both lamps) 30 minutes after the
circuit was energized, and turn it OFF 30 minutes later – Use CB #1 as
B) The Motion Sensor has to turn ON the relay to enable the Starter what will allow an operator
to START (turn ON) the motor – CB #2.
The Motor will turn OFF under two possible conditions:
a. The Sensor stops sensing motion
b. The operator STOPS the motor (turns OFF pressing the STOP PB)
Assign numbers to the wires; draw two terminal block (TB) diagrams based on the next ad-hoc
ladder logic schematic. BEFORE connect anything, show the diagrams to your instructor.
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TB diagrams
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Connect and, with your instructor, test your circuits.
Measure the current that the control components (ONLY) are drawing from CB#2. Suppose that the
motor will be changed by a 480VAC unit
Now the circuit will be change for
Select a transformer and a fuse for the new control circuit
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LAB #4a – Control Circuits – 2nd part
READ _ UNDERSTAND _ PLAN YOUR WORK _ WORK YOUR PLAN
Tool set - Provided

A V-Ω-A meter
Not provided
1/16 slot screwdriver
Safety goggles
Materials - Provided
A tray with an Allen Bradley VFD PowerFlex 40 22B-V2P3N104, a 0.13 HP
3φ motor and a control station with a selector switch, 3 push buttons (two NO, one NC),
1 pilot light, a PB mushroom E-stop, a 120 VAC DP NO-NC relay, a 120 VAC timer,
and a 3 wire cord with a plug.
Not provided
Red, blue, and white AWG #16 wire – 2 feet each, – black AWG #14 – 1 foot. -
Tasks
1. Identify terminals at the terminal blocks and draw a TB schematic.
2. Based on the TB schematic and the provided control circuit, draw a wiring
diagram in correspondence with the control circuit (ladder logic.)
3. Show your circuit to the instructor for verification
4. Perform the necessaries connections – Show and have it approved by instructor
5. With instructor - Input VFD’s parameters
6. Test
7. Complete items at the end of the lab (after the VFD user’s manual)
TB schematics
Wiring diagram
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What are these parameters setting?
P033 –
P034 –
P035 –
P036 –
P037 –
P038 –
A054 –
A055 –
A069 –
If field conditions ask for jogging the machine forward – What should the electrician do? Give two
possible solutions.
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LAB #4b – Field device wired with IMC and FMC
Tool set - Provided
A Mechanic Bender
A tri-stand
A pipe cutter and a hack saw
A reamer
Slip-joint pliers and a pipe wrench
A tape measure, a level, a protractor, and a square
Safety goggles
Gloves
Working boots
Materials
10’ IMC ¾” trade size

A piece of IMC ½” trade size
Two feet of ½” FMC
A frame provided with a motor control unit w/a Square D NEMA 1 starter, a start-stop
station, a three phase motor disconnect, and a 3-phase 208V ¼ HP motor
Conductors – THW AWG #14 – Blue, Red, White, Green, Yellow, Orange and Brown
Project
The frame with the

enclosure, the start-stop
station and the motor
disconnect, simulates a
pump, or an elevator, a
conveyor, a wrapper,
anything that is wired in
the middle of an empty
space in a warehouse.
The mechanical
junction point to the
main raceway can be
aligned or not with the
machine due to
- 365 -
conditions in the area where the machine will be installed. Two different cases are presented in the
illustration above. The frame will be put in place by the instructor and, of course, it will not be
aligned with the hubs in the wireway. Then, one of the illustrated options has to be chosen.
Task #1
Run IMC ¾” conduit from the over-head 4x4 wire way to the Motor Control unit
Run IMC ½” conduit from the motor control to the Motor Disconnecting Mean.
Run FMC from the motor control to the Start-Stop station and from the Motor Disconnect to the
Motor.
Procedure
IMC ¾”
1. Measure the distances between the hub in the wireway to the hub in the control panel
following an orthogonal path (90º) – END to BACK, and BACK to END. Ignore the offset
between targets. Add them. This is “MEASURE 1”
2. Measure the offset between targets. This is “MEASURE 2”
3. Decide type of bends to perform, besides the obliged 90º to reach the wireway.
There are not technical reasons to select a KICK over an OFFSET, sometimes there are
conduits already in position and the new runs have to follow the established layout, but if
this is going to be a solitary drop, a KICK will perform as well as an OFFSET. The
reason to select one over the other has to do with preferences. Suggestion: make KICKs
for offsets bellow 12” and OFFSETs for offsets of 12” or above
4. Subtract from MEASURE 1 the bender’s GAIN, and hubs depth. Add shrink for OFFSET
based on MEASURE 2. If the job is going to be done using a KICK, then estimate the
SHRINK like if it were for an OFFSET.
5. CUT, REAM, and THREAD
6. Mark the STUB and bend the 90º
7. From the back of the 90º mark your KICK mark, or your OFFSET marks
8. Proceed to bend. Beware of the order, and direction of the bends, as well as dog-legs (if
bending an OFFSET)
9. Check bends along the job and verify, and correct if needed, angles and length - Check your
conduit work with instructor.
IMC ½”
- 366 -
1. Perform measurements and determine conduit length
2. CUT, REAM and THREAD.
3. Perform bend or bends
4. Check bends along the job and verify, and correct if needed, angles and length - Check your
conduit work with instructor.
FMC
1. Measure the arc from the motor-disconnect enclosure to the motor’s connection box, and
from the motor-control enclosure to the start-stop station
2. Measure FMC and cut as indicated
3. Install FMC fitting carefully
- 367 -
Is the current measured equal, larger or smaller than the FLA of the motor?
Are the amps at all the legs the same? YES NO Why?
What amp reading you may expect if the motor were running overloaded? (State a definitive value as
reference, i.e.: If the reading were steady over X amps)
- 369 -
- 370 -
LAB #4c – for teams of 3
Wiring project using EMT, IMC, FMC, and MC cable
Tool set - Provided
A Mechanic Bender
A tri-stand
A pipe cutter and a hack saw
A reamer
Slip-joint pliers and a pipe wrench
A tape measure, a level, a protractor, and a square
Safety goggles
Gloves
Working boots
Materials
120” IMC trade size ¾”

60” IMC trade size ½”
60” EMT trade size ¾”
60” EMT trade size ½”
60” FMC trade size ½”
120” MC cable
Condulets and fittings.
Wire TW AWG #14 – several colors
Wire-nuts
A frame provided with U-struts to hung enclosures, a safety switch without fuses, a 8’ cord
terminated in a sleeve and pin plug, a start-stop station provided with two PBs, a motor disconnect,
and a fractional power 3φ motor.
Two Square D MCC panels to be used as enclosures, one empty and another with a NEMA 1 – 1HP
starter, and a Wiegmann enclosure.
Hardware – nuts, washers, and bolts
A high-bay HID fixture w/ballast and lamp.
Back-panels with relays, timers, control CBs, and other elements for the project
- 371 -
Project
Using the frame as a machine and as a wall run conduit (IMC and EMT), FMC and MC cable to
wire:
A) A 3φ 208 VAC motor,
B) A HID fixture, and
C) Wall outlets (an outlet with a 3 way circuit and a duplex receptacle).
These three circuits are fed from the power strip downstream of the main disconnect.
B and C come from the same panel.
Run ¾” IMC from the main disconnect to a “T” type condulet, and from there continue ¾” IMC to
motor panel and ¾” EMT to circuits B and C panel.
- 372 -
3φ 208 VAC motor
Sketch circuits BEFORE start pulling wires
IMPORTANT: The motor shall not start without an ALARM announces during 3 seconds that the
motor is about to run.
Wiring methods: IMC and FMC
- 373 -
Single phase circuits
Sketch circuits BEFORE start pulling wires
Wiring methods: IMC, EMT, FMC, and MC cable
- 374 -
YOUR NOTES
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- 376 -
Environmental Heath & Safety
Based on the safety guidelines of the Florida State University - Department of Environmental
Health and Safety, please answer the next questions
1. Why is not permitted to drill holes in the shell of a hard hat?
A. Lowers electrical insulation

B. Increases electrical insulation
C. Decreases mechanical resistance
D. A and C
E. B and C
2. What national standard does cover protective footwear?
A. ANSI Z89.1-1986
B. ANSI Z87.1-1968
C. ANSI Z41-1991
3. When eye protection shall be worn?
A. Not unless the risk is evident

B. When performing work tasks with potential eye hazards
C. In areas identified as containing the potential for eye injury
D. B and C
E. All of the above
4. Hand threading and deburring metal edges do not fall under the conditions that demand
the use of working gloves.
A. True
B. False
5. What type of gloves should be worn when there is a potential for injury from being struck
against, caught between, cut, or punctured, and material handling?
A. PVC
B. Butyl rubber
C. Leather or cotton
D. Neoprene
6. What type of gear does make a “fall arrest system”?
-
-
7. Are body-belts considered a “fall arrest system”?
A. YES
B. NO, they are prohibited
8. What are the conditions that require the use of hearing protection?
-
-
9. When inspection of hard hats shall be performed?
A. Once a month
B. Once a year
C. Prior each use
10. List the issues that should be observed
-
-
-
-
-
-
-
11. How often inspection of foot protection should be performed?
A. Once a month
B. Once a year
C. Prior each use
-
-
13. How often inspection of eye and face protection should be performed?
A. Once a month
B. Once a year
C. Prior each use
-
-
-
15. How often inspection of hand protection should be performed?
A. Once a month
B. Once a year
C. Prior each use
-
-
-
17. How often inspection of fall protection systems should be performed?
A. Once a month
B. Once a year
C. Prior and after each use
-
-
-
-
19. When is acceptable to carry chisels, punches or other sharp tools in clothes pockets?
A. Always
B. Never
C. Depending on the circumstances
20. When dealing with extra-tight pipes it is correct to increase the leverage of the pipe
wrench by adding an extension to the wrench’s handle.
A. True
B. False
21. Screwdrivers must never be used as punches, wedges, pinch bars or pries.
A. True
B. False
22. It is recommended to carry a knife into the sheath on the front part of a belt
A. True
B. False
23. Pliers are not substitutes for wrenches
A. True
B. False
24. Hacksaws’ blades have to be installed with teeth pointing forward
A. True
B. False
25. When working with power tools with revolving parts such as drills, saws, and grinders,
loose fitting clothing, long hair or jewelry must not be wear.
A. True
B. False
26. List the five primary groups of portable power tools, based on the power source that
drives the tool.
-
-
-
-
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Conduit Bending – Exercises
Complete the next chart
½” EMT HB
Take-up
Gain
Set-back
How much conduit is required to bend a 90º with a 35” stub and 56” leg, if the gain of the bender
is 3 3/8”?
What is the distance between bends to perform a 15” offset using 45ºs?
What is the shrink for a 8 ¾” - 45º offset?
How much conduit would be necessary to connect two points 186” apart and having 16 ½” offset
between them? [FST angle = 30º]
Wiring Components and Devices
Based on AFC technical article, the cord list, and the Automation Direct enclosures tech spec;
answer the next questions
1. What is the difference between AC and MC cables?
2. What NEC articles cover AC and MC cables?
3. What is the voltage rating of SO and ST cords, and what is the difference between them?
4. Where NEMA 1 enclosures are used?
5. What NEMA rating is required for enclosures used in areas with occasional whasdown?
6. What NEMA rating is required for enclosures used in meet/poultry processing facilities?
OCPDs
Based on the Pass & Seymour’s “Overview of 2005 NEC Code Changes” technical article, and
the UL’s excerpts on “AFCI – Types and Performance considerations” technical article; answer
the next questions.
1. All 15A and 20A, 120V receptacles in commercial and institutional kitchens must be
GFCI protected.
a. True
b. False
2. When an outdoor receptacle in a public space could not be GFCI protected?
a. Never
b. When are protected by a some weatherproof hood
c. When are not readily accessible and supplied from a dedicated branch circuit
3. In agricultural buildings it is not required GFCIs in dirt confinement areas for livestock
a. True
b. False
4. What is the radius of the area around a fountain where GFCIs are mandatory?
a. 20 feet
b. 30 feet
c. 5 feet
5. What is a “series arcing fault”?
6. What is a “parallel arcing fault”?
7. What UL standard does address the different types of AFCI?

8. Where are installed and what is the purpose of Branch/Feeder AFCIs?
9. What is an Outlet Circuit AFCI?

POWER SOURCES
Based on Square D – Low Voltage selection guide and GE’s technical article “The Digital World
and Electrical Power Supply”; answer the next questions
1. What are K-rated transformers? What are they used for, and what are they not?
2. What is the application of general purpose dry type transformers?
3. What type of general purpose dry type transformers are there?
4. What are and what are the applications of buck and boost transformers?
5. What are the inrush and the excitation currents of transformers?
6. What factors are relevant for the amount of short circuit current a transformer can
deliver?
7. Can transformers with Delta primaries be used on Wye systems?
8. List the five typical problems in the utility power network that need to be addressed to
protect sensitive electronic systems.
9. List the basic types of UPS, and briefly describe what are their advantages and
disadvantages?
GROUNDING
Based on TM 5-864 Chapter 10 – excerpts – answer the next questions
1. Which conditions do primarily determine the ground resistance?
A. The earth surrounding the ground electrode

B. The diameter of the rod
C. The length of the rod
D. A. and B.
E. A. and C.
F. B. and C.
G. A. B. and C.
2. Which factors can degrade the good conditions of grounds?
-
-
-
-
3. Which important safety measures must be taken when performing maintenance tasks upon
grounds? Indicate all that applies
a. There is not safety measures since the ground is at zero potential

b. Never open a ground connection unless the equipment is de-energized or a safety
bypass is provided
c. Wear rubber gloves
4. How often a thoroughly visual inspection should be performed over ground systems?
a. Every other month

b. Twice a year
c. Every two year
5. NEC250.52 (5) (b) lists stainless steel as a possible material to be used as ground electrode.
What is the potential problem that such type of electrodes might face due to galvanic
conditions in the ground?
6. What other maintenance provision shall be made besides visual inspections?
a. Short circuit test

b. Resistance measurements
7. List the ground resistance measurement that should be made in order to ensure safe operating
practices.
-
-
-
-
-
-
8. List the methods to reduce ground resistance
-
-
-
-
-
COMMERCIAL and INDUSTRIAL LOADS
Based on Grainger cat No 399 tech specs, and answer the next questions
1. What are the start and the restart characteristics of HID lamps?
2. When relamping should be performed in HID systems and why?
3. What is the basic constitution of HID lamps whether they are Metal Halide, Multi-Vapor, or
Mercury lamps?
4. Why lamps shall be protected from accidental contact with water, even droplets?
5. What are Quartz Restrike Fixtures?
6. What is the minimum mounting height for High Bay Fixtures?
7. What are the most relevant pieces of information that an electrician needs to know when
selecting a motor?
-
-
-
-
-
-
-
-
-
-
-
-
8. What are the characteristics and application of General Purpose Motors?
9. What A and B should measure in the sketch bellow if this were the bracket for motor NEMA
frame 284TS?
A=
B=
10. What provisions should be taken for motors that start automatically and are located out of
operator sight?
11. What applications are prohibited for motors with automatic reset thermal protection?
12. What does UL 507 standard establish?
13. What type of motor enclosure is rated IP45?

14. List the basic types of bearings used on electric motors
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15. List the basic types of motor housings
-
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16. What is the operating temperature of a Class F motor
17. List the basic types of motor mountings
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- 377 -
KNOWLEDGE
CRAFTMANSHIP
TENACITY
INTEGRITY
- 378 -

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-1-

Glossary of terms and abbreviations 6

Florida Sate University – Department of Environmental Health and Safety 57

AC, MC and HCF cables – FAQ 95

Commercial & Industrial Wiring – Lab Guide 325

Lab #1 Bending with Hand Benders – EMT 327

Glossary of basic terms

15º 22.5º 30º 45º 60º

ZC = 3.73 ZC = 1.73 ZC = 1.00 ZC = 0.58

KP 4.4 4.06 3.99 4.13 4.46

KP 5.84 5.50 5.50 5.90 6.55

KP 7.63 7.22 7.23 7.72 8.54

RC and SNKC are valid for HB as well as Electric Benders

Offsets Down – See illustration

Saddles using HBs

3 bends saddles (22 ½ - 45 – 22 ½ )

Without changing the radius

PERSONAL PROTECTIVE EQUIPMENT AND CLOTHING GUIDELINES

HAND TOOLS GUIDELINES

POWER TOOLS GUIDELINES

Look for more resources at www.safety.fsu.edu

It is the intent of The Florida State University (FSU) to provide every

Where feasible, appropriate engineering and/or administrative controls will

This manual has been developed by the Department of Environmental Health

A Hazard Assessment of the workplace shall be conducted by the Supervisor

The Industrial Hygiene Coordinator will assist the supervisor/user employee

Supervisors shall ensure that employees wear the appropriate PPE.

Employees shall be responsible for properly donning, doffing, wearing,

Training will be provided or contracted by EH&S.

Employees shall wear protective helmets when working in areas where

Personnel shall wear adequate foot protection when working in areas

3. Eye and Face Protection

Employees and students shall use appropriate eye or face protection

Eye protection shall be worn in areas identified as containing the

Prescription safety glasses shall be provided to those employees that

Personnel wearing contact lenses shall exercise extreme care when

The selection of protective eyewear (filter lenses and plates) for

The selection of protective eyewear for laser users shall be based on

Employees shall use appropriate hand protection when hands are

There is no single glove which provides protection against all potential

When working with liquid hazardous chemicals, gloves such as rubber,

Leather or cotton gloves shall be worn when there is a potential for

Gloves designed to protect from temperature extremes shall be worn

Electricians shall wear insulated rubber gloves meeting the

Gloves should not be worn when operating equipment such as drill

A large variety of chemical protective clothing (CPC) types and

Coveralls provide total body protection from potential exposure to

Lab coats should be worn in all laboratories where hazardous

6. Fall Protection - Personal Fall Arrest Systems

Each employee on a walking/working surface (horizontal and vertical

Exceptions to using personal fall arrest systems:

o When employees are making an inspection, investigation, or

Harnesses, lanyards and lifelines shall be used only for employee

Personal fall arrest systems and components subjected to impact

Respiratory protective devices shall be worn when the use of

Employees that are required to wear respiratory protective equipment

Hearing protection is required in areas where the sound level exceeds

Employees that are required to wear hearing protective equipment

Personal protective equipment requires proper cleaning, decontamination,

Cleaning and decontamination includes the washing of equipment with