Common Hazard Sources

Wiring Issues

Risk Factors:

Damaged or frayed wires increase risk of arc, shock, and short circuit
Exposed conductors visible outside of connectors create increased risk of arc and short circuit
Messy wire strands increase the risk of short circuit

Damaged DC conductor with melted PVC coating showing fire risk hazard — *Damaged DC conductor with melted PVC coating - This creates immediate fire risk and potential for arc flash*

Heat damage causing hardened and cracked conductor sheathing with exposed wires — *Heat damage causing brittle insulation - Hardened sheathing cracks and exposes conductors, creating shock and arc hazards*

Frayed wire strands creating electrical arc hazard — *Frayed wire strands - Messy strands increase risk of short circuits and arcing between conductors*

Poor wiring connection without ferrules using oversized wire gauge — *Improper termination - Missing ferrules and oversized AWG wire for connector rating creates fire and arc flash risks*

High Voltage Enclosure Commissioning and Service

Key Risks:

Powering on a panel for the first time is one of the most likely times for short circuit events

Best Practices:

Measure line-to-line and line-to-ground resistance with a mega ohm meter or HI pot before commissioning to verify there is no short circuit
Always unplug power and de-energize the system before inspecting it
If you believe de-energizing is not feasible, clear your plan with Jon or Johannes before proceeding

High voltage enclosure showing proper commissioning safety procedures — *High voltage enclosure commissioning - Always measure insulation resistance before first power-on to prevent short circuit events*

Test Setups

The highest risk scenarios are test setups that work with high voltage AC or DC power. In our efforts to move quickly, we cannot forget to take steps to be safe.

Safety Requirements:

Use over current protection: circuit breaker, fuse, or power supply with limited current capability
Insulate live voltages using appropriate materials:
- Vinyl sheet and Kapton tape for low temperature systems
- Fiberglass-based insulation for high temperature applications

*High voltage Vinyl Arc Barrier - Provides enclosures with overcurrent arc protection, essential for test setups above 60V*