Electrical measurement safety

Understanding hidden
hazards and new safety
standards

©2003 Fluke Corporation Electrical measurement safety 1

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

©2003 Fluke Corporation Electrical measurement safety 2

Handheld test tool safety
How not to save time...
Last known earthly
residence of
automotive fuse
used to replace
original fuse

Test leads survived intact

©2003 Fluke Corporation Electrical measurement safety 3

Handheld test tool safety
This DMM had a hot date with 13.8 kV.
13.8 kV
arced Test leads destroyed
over to
test
probes.

Insides were barbecued.

©2003 Fluke Corporation Electrical measurement safety 4

Handheld test tool safety
The wrong meter to use on a power circuit.
250V fuse
didn’t open
in time

Probe tips Poor quality leads and

burned off probes led to injury.

©2003 Fluke Corporation Electrical measurement safety 5

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

©2003 Fluke Corporation Electrical measurement safety 6

Handheld test tool safety
Typical work environment

©2003 Fluke Corporation Electrical measurement safety 7

Handheld test tool safety
Aftermath of an accident

©2003 Fluke Corporation Electrical measurement safety 8

Handheld test tool safety
If it melts metal, what does it do to people?

©2003 Fluke Corporation Electrical measurement safety 9

Common DMM / tester hazards
• Arc from transients (lightning, load switching)
Protection: Independent certification
to meet CAT III-1000 V or
CAT IV 600 V
• Voltage contact while in continuity or resistance
Protection: Overload protection in OHMs up to the meter’s volt rating
• Measuring voltage with test leads in current jacks
Protection: High energy fuses rated to the meter’s voltage rating
Use meters / testers without current jacks
• Shock from accidental contact with live components
Protection: Test Leads double insulated, recessed / shrouded,
finger guards, CAT III – 1000 V. Replace when damaged
• Using meter or tester above rated voltage
Protection: Good karma

©2003 Fluke Corporation Electrical measurement safety 10

Common DMM safety hazards
Three common errors that are avoidable
• Measuring voltage while test
leads are in the current jacks:
short-circuit!
Protection: Fluke meters use
high energy fuses.
• Contact with ac or dc power
source while in Ohms mode.
Protection: Use a meter with “Overload Protection”.
Functions are self-protected to the meter’s rated
voltage.
• Using meter above rated voltage, i.e., on medium
voltage circuits.
Protection: Good karma

©2003 Fluke Corporation Electrical measurement safety 11

Safety inspection
Test leads and probes
Check test lead resistance:
Step 1: Insert leads in V/  and COM inputs.
Step 2: Select  , touch probe tips. Good leads are 0.1 - 0.3 .
How do you check a single test lead?
Visually check for:
• CAT III-1000 V/CAT IV-600 V rating
• Double insulation
• Shrouded connectors, finger guards
• Insulation not melted, cut, cracked, etc.
• Connectors not damaged: no insulation pulled away from end
connectors
• Probe tips: not loose or broken off

©2003 Fluke Corporation Electrical measurement safety 12

Safety inspection
Checking meter fuses on most meters
Step 1: Plug test lead in V/  input. Select  .
Step 2: Insert probe tip into mA input. Read value.
Step 3: Insert probe tip into A input. Read value.
Is the fuse okay? What would an open fuse read?

©2003 Fluke Corporation Electrical measurement safety 13

Safety Inspection
Overload protection on volts inputs

With leads in V/  and COM inputs:

Step 1: Select V and put probes

in a live outlet.
Will you damage the meter if you...

Step 2: Select mV
Step 3: Select 
Step 4: Select A.
Overload protection is only to DMM’s rated voltage.

©2003 Fluke Corporation Electrical measurement safety 14

New IEC Safety Standards

©2003 Fluke Corporation Electrical measurement safety 15

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

©2003 Fluke Corporation Electrical measurement safety 16

IEC 61010 key concepts
Protection against overvoltage transients
• CATEGORIES: CAT I to CAT IV
• The greatest danger from transients is in
the high categories, because they could
trigger an arc blast.
• IMPULSE TESTING: No failure allowed
• Meters must be tested by being hit with a
specified number of transients, with
specified peak voltages.
• INTERNAL SPACING: increased
• Clearance (distance through the air) and
• Creepage (surface distance) are increased.

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Overvoltage category
• The level and energy of voltage impulses is
dependent on the location. The closer the location
is to the power source, the higher the available fault
current, the higher the category

• IEC 61010 defines four locations or categories:

CAT IV “Origin of installation”
Utility level and any outside cable run
CAT III Distribution wiring, including “mains” bus, feeders
and branch circuits; permanently installed loads.
CAT II Receptacle outlet circuit; plug-in loads.
CAT I Protected electronic circuits

©2003 Fluke Corporation Electrical measurement safety 18

Category locations

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Overvoltage category
Common sense ways to think of categories
• The higher the short circuit fault current available,
the higher the category
• High energy transients are much more dangerous,
because they can trigger an arc blast
• The greater the source impedance, the lower the
category
• Transients are dampened by system impedance as
they travel from the point where they were generated.
• TVSS (transient voltage surge suppression)
devices are sized larger (more joules) at the
panel than at the receptacle outlet.

©2003 Fluke Corporation Electrical measurement safety 20

Determining the true voltage
withstand rating
WITHIN each Category:
• There are designated “working voltages”
(50, 150, 300, 600, 1000 V).
• A higher voltage has a higher transient withstand
• CAT IV example:
CAT IV – 600 V: 8 kV impulse
• CAT III example:
CAT III – 600 V: 6 kV impulse
CAT III – 1000 V: 8 kV impulse
• CAT II example:
CAT II – 600 V: 4 kV impulse
CAT II – 1000 V: 6 kV impulse

©2003 Fluke Corporation Electrical measurement safety 21

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

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First the CAT, then the voltage
• Voltage rating by itself can be misleading.
• CAT III-1000 V (8 kV transient) is safer than CAT III-600 V
(6k V transient)
• But CAT III-600 V is safer than CAT II-1000 V

• First know the category you are working in, then choose
the appropriate voltage rating.
• If you ever measure power circuits, you should use
a CAT III-600 V or CAT IV 600 V/CAT III-1000 V meter.
• And CAT IV 600 V/CAT III-1000 V test leads and probes.

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Look for CAT III or CAT IV markings

CAT III- CAT IV-600 V CAT III-

1000 V CAT III-1000 V 600 V

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Levels of CAT III protection

CAT Transient with Fuse and Clearance Creepage

2  Source overload (air) (surface)
Rating
III-1000 V 8000 V 1000 V 16.0 mm 16.0 mm
IV-600 V
III-600 V 6000 V 1000 V 11.5 mm 14.0 mm
II-1000 V
II-600 V 6000 V 600 V 11.5 mm 11.5 mm

©2003 Fluke Corporation Electrical measurement safety 25

“Listed” vs. “designed to”
IEC sets standards but does not test or inspect
for compliance.
A manufacturer can claim to “design to” a
standard with no independent verification.
To be UL-Listed, CSA or TUV-Certified , a
manufacturer must employ the listing agency to
TEST the product’s compliance with the standard.
Look for the listing agency’s emblem on the meter.

©2003 Fluke Corporation Electrical measurement safety 26

“Designed to IEC 1010-1”
But can the product pass testing...
Brand A Brand B Brand C
Markings CAT II – 750 V CAT III D of C to
1000 V Input IEC 1010-1
Tested @ CAT II – 1000 V Cat III – 1000 V CAT III – 1000 V

3.7 mm 2.5 mm 7.5 mm

Creepage Doesn’t Doesn’t Doesn’t
clearance comply comply comply
with 5.7 mm with 16 mm with 16 mm

Input protection Display Input protection

Transient components window components
tests opened breakdown opened
under high @ CAT II level
voltage

©2003 Fluke Corporation Electrical measurement safety 27

 1 Flashover inside meter 2 Fault current in test leads

3 Arcing at the terminals 4 Arc blast

©2003 Fluke Corporation Electrical measurement safety 28
Misuse of DMM in ammeter mode

©2003 Fluke Corporation Electrical measurement safety 29

Fuse protection on amps inputs

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

CAT IV-600 V
CAT III-1000 V

©2003 Fluke Corporation Electrical measurement safety 31

What’s the bottom line?
• If you use a scope on power
circuits, you need a CAT III-600 V CAT III-600 V
scope and scope probes.
• Look for the CAT rating and voltage
rating marked near the input jacks.

©2003 Fluke Corporation Electrical measurement safety 32

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

1000V high CAT IV-600 V

energy fuses CAT III-1000 V

©2003 Fluke Corporation Electrical measurement safety 33

What about my old meter?
Unless a meter was specifically designed to
meet CAT III-600 V or higher, it is not safe to use
on power circuits. Most meters produced before Newer meters also have
additional features and
1997 do not meet the standard. capabilities
Larger displays
Back light
1000 Vac capability
Capacitance
Frequency
Magnetic hangers
Temperature
3X dc accuracy
2X ac accuracy
Original Older Fluke New 170 Series Min / Max Record
Fluke 70 Series 70 Series-III CAT IV-600 V Probe holders
NOT RATED CAT II-600 V CAT III-1000 V Battery door
UNDER RATED

©2003 Fluke Corporation Electrical measurement safety 34

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

©2003 Fluke Corporation Electrical measurement safety 35

Meter safety checklist
Watch for:
• Cracked or oily case
• Broken input jacks

No meter is safe when improperly used.

• Use meters within their rating.
• Use meters designed for measurements on
power circuits.
• Use replacement fuses approved by the
manufacturer.

©2003 Fluke Corporation Electrical measurement safety 36

Test lead safety checklist
Don’t let test leads be a weak point
• CAT III-1000 V or CAT IV 600 V/
CAT III 1000 V rating
• Double insulation
• Shrouded connectors
• Arc Flash Hazard consideration using
specialized probes and PPE materials
• Finger guards
• Insulation not damaged: not melted, cut,
cracked, stretched
• Connectors: no insulation pulled away
from end connectors
• Probe tips: not loose or broken off (too short)

©2003 Fluke Corporation Electrical measurement safety 37

Safety first
Safe practices include but are not limited to:
• Whenever possible, work on de-energized circuits.
Follow proper lock-out/tag-out procedures.
• Use well maintained tools and appropriate safety gear
• Safety glasses, insulated tools, insulating gloves,
flash suits, insulating mats, etc.
• Don’t work alone.
• Practice safe measurement techniques.
• Always connect the grounded lead first, hot second.
• Disconnect the hot lead first, grounded lead second.
• Use the three-point test method.
• Test known circuit, measure target circuit,
then re-test known circuit.

©2003 Fluke Corporation Electrical measurement safety 38

Oscilloscope safety
Category ratings
• Select a scope and probes
and clamps for the worst
case category

Voltage ratings
• Working voltage
• Transient voltage
Overvoltage Working voltage Peak impulse Test source
category (dc or ac – rms to grnd) transient (Ohm = V/A)
(20 repetitions)
CAT I 600V 2500 V 30 ohm source
CAT I 1000V 4000 V 30 ohm source
CAT II 600V 4000 V 12 ohm source
CAT II 1000V 6000 V 12 ohm source
CAT III 600V 6000 V 2 ohm source
CAT III 1000V 8000 V 2 ohm source

©2003 Fluke Corporation Electrical measurement safety 39

Oscilloscope safety
Line powered bench scopes
• Use a differential or isolation probe
to separate the earth ground
connection of the scope from high
energy circuits that are also
referenced to earth ground.
• Isolate bench scope grounds only
in conjunction with
differential/isolation probes.

Differential 50Ω BNC

Input Output

©2003 Fluke Corporation Electrical measurement safety 40

Oscilloscope safety

DC VOLTAGE

TO MOTOR

DC VOLTAGE

Typical use of a differential probe

©2003 Fluke Corporation Electrical measurement safety 41

Oscilloscope safety
Battery powered scopes -
• Have inherent ground isolation for superior
common mode noise rejection
• Some come standard with CAT III 600 volt probes
for measurements in high energy circuits

©2003 Fluke Corporation Electrical measurement safety 42

Oscilloscope safety
Probes
• Beware of bench scope probes - they are usually
CAT I - 500 volts
• Don’t use CAT I or II divider probes on CAT III circuits
• Don’t use probes with exposed metal parts
• Don’t use probes without specified ratings
• Read the manual for safe probe connections - they
may vary greatly between instruments

©2003 Fluke Corporation Electrical measurement safety 43

Oscilloscope safety
Safe practices
• De-energize circuits
• Use protective gear
• Do not exceed instrument voltage and category ratings
• Use dc coupling - ac coupling may not reveal
dangerous voltages
• Use 3-point test method
• Test known live circuit
• Test target circuit
• Test known live circuit again
• Avoid holding or touching the scope if possible

©2003 Fluke Corporation Electrical measurement safety 44

Oscilloscope safety
Current clamps
• Clamps have category and working voltage ratings
• Do not exceed them

CAT III circuits - Make sure

you use Cat III leads AND
scope AND current clamp

©2003 Fluke Corporation Electrical measurement safety 45

What’s the bottom line?
• If you use a scope on power circuits, you need a
CAT III-600 V scope and scope probes.
• CAT II scopes and probes are mainly for loads
that plug into a receptacle outlet.

CAT III-600 V

©2003 Fluke Corporation Electrical measurement safety 46

CAT IV

Equipment of overvoltage category IV

is for use at the origin of the installation
(utility service).
• Outside and service entrance
• Service drop from pole to building
• Run between meter and panel
• Overhead line to detached building
• Underground line to well pump22

©2003 Fluke Corporation Electrical measurement safety 47

CAT III

• Premises wiring: “mains”circuits, i.e.,

bus and feeders and distribution panels
• Permanently installed loads: motors,
lighting systems, drives, load centers
• Typically separated from utility service
by at least a single level of transformer
isolation
• Does not include receptacle plug-in
loads, except in the case of heavy
appliance outlets with “short”
connections to service entrance

©2003 Fluke Corporation Electrical measurement safety 48

CAT II

Loads that plug in at receptacle outlet

• Examples of such equipment are
appliances, portable tools and other
household and similar loads
• All outlets at more than 10 m (30 ft)
from Category III
• All outlets at more than 20 m (60 ft)
from Category IV

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CAT I

Equipment in which measures are

taken to limit transient overvoltages
to an appropriately low level
Examples are protected electronic
circuits. A copier that has an internal
step-up transformer and 1000 Vdc is still
a CAT I-1000 V machine, because the
current levels are so low

©2003 Fluke Corporation Electrical measurement safety 50