02 Personal Safety PDF

Automation and Drives
Personal Safety
with
Medium Voltage Drives
04 Personal Safety page 1 © Siemens Industry 2013 - subject to modification
Table of Contents
Content Page
Safety Precautions ..................................................................................................................... 3
Electric Shock Hazards ............................................................................................................. 5
Arc Flash Hazards .................................................................................................................... 6
Areas and Boundaries ............................................................................................................... 7
PPE – Levels ............................................................................................................................. 9
PPE – Personnel Protective Equipment ...................................................................................... 10
Verifying the De-Energized Condition.......................................................................................... 12
Personnel Safety in Switching Operations................................................................................... 14
Components carrying Medium Voltage ( > 1000 V )..................................................................... 15
Components carrying Low Voltage ( < 1000 V )........................................................................... 16
Medium Voltage Circuit Breaker (at Input of VFD)....................................................................... 17
Grounding the VFD and its Environment..................................................................................... 20
External Main Power Verification................................................................................................. 21
One Source of Isolation for the Medium Voltage.......................................................................... 22
Two Sources of Isolation for the Medium Voltage........................................................................ 23
Isolating the Output (e.g. for Motors with long Lead Length)........................................................ 24
Isolating the Output (Motor with Bypass Capability)..................................................................... 25
Isolating the Output (Motor with Parallel Drives).......................................................................... 26
Parallel Drives on Synchronous Motor with Exciter...................................................................... 27
External Main Power Verification.................................................................................................. 28
General Safety Precautions......................................................................................................... 29
Mechanical Key Interlock (Standard)........................................................................................... 30
Mechanical Key Interlock (System “Areva”)................................................................................. 31
Electromechanical Interlock......................................................................................................... 32

Safety Precautions
Numerous exposed connections present lethal voltages.
Only qualified individuals should install, operate,

troubleshoot and maintain the drive.
Verify that all power is off before you work on the

equipment.
Never touch anything within the drive cabinets

until verifying that it is neither thermally hot nor
electrically alive.
Never assume that by switching off the circuit

breakers all of the voltage is removed from inside
the cabinet.
Voltage is still present on the terminals of the input

www.safetysign.com
circuit breaker.
There may be voltages present that are applied from other external sources.
Safety Precautions
Always follow proper lock-out / tag-out procedures (lock-out / try-out)

before beginning any maintenance or troubleshooting work on the drive.
According to local regulations, an “Energized Work Permit” may be required.
Work with one hand, turn away, keep a distance.
Wear insulated or rubber safety shoes.
Wear safety glasses and hearing protection.
Use appropriate equipment for checking low voltage, medium voltage
www.safetysign.com

Electric Shock Hazards
Voltages may drive a current through your body.

Depending on its amplitude, there may be various effects.
Arc Flash Hazards
Released arc flash energy causes following hazards to health or life:

Thermal
Arc flash temperatures can reach 20.000°C (35.000°F ); the surface of the
sun is 5000°C (9000°F); skin cell destruction after 1s at 70°C (or 158 °F);
incurable burns will occur after 0.1s at 96 °C (205 °F) for > 1.2 cal/cm 2.
according to NFPA 70E: ArcFlashBoundaryDistance = (2.6 x MVAbf x t)1/2
e.g. 4MVA transformer at 5% uK ( 80MVAbf) and 0.2s: ArcFlashBoundaryDistance = 2 m (for <1.2 cal/cm2)
The emitted light is very intense and will damage the retina of the
unprotected eye, often permanently.
Pressure
Pressure wave up to 14.400 Pa (300lb/ft2) may cause appr. 227kg
(500lbs) thrust onto exposed body surface.
e.g. a 3 phase 20kA short circuit at 100V arc voltage for 0.2sec is equal to about 0.3kg TNT.
Auditory
Pressure levels can exceed 160dB; a gun blast is only 140dB or 200Pa,
e.g. only 1/10 of that pressure level. Irreversible damage to the ear will
occur at 120dB or more, which is only 1/100 of that level.
Projectile
Molten metal and broken parts will be ejected at high speed resulting in
severe burns and cuts.
Inhalation “Large arc flashes are rare (5-10 per day in the US);
when they happen, they are life-changing events.“
Extremely hot air, molten metal and/or vaporized metal, as well as burning Jim White, Shermco Industries Inc., in: Plant Engineering, April 2010
insulation smoke and fumes will damage lungs and respiratory tract.

Areas and Boundaries
Boundaries from NFPA70E
NFPA 70E 2012 Table 130.4(C)(a) shows

approach boundaries for various voltage levels.

PPE Levels (Personal Protection Equipment)
Hazard/ Clothing Description Required Minimum

Risk (Typical number of clothing layers in Arc Rating of PPE
Category parentheses) [J/cm2 (cal/cm2)]
Non-melting, flammable materials
(i.e. untreated cotton, wool, rayon, silk or
0 N/A
blends of these materials) with a fabric
weight of at least 4.5 oz/yd2
Arc Rated FR Shirt and FR pants or FR
1 16.74 (4)
Coverall
Arc rated FR shirt and FR pants or FR

2 33.47 (8)
Coverall

3 104.6 (25)
Coverall and Arc Flash Suit

4 167.36 (40)
Coverall and Arc Flash Suit
NFPA 70E 2012, table 130.7(C)(16)
PPE – Personnel Protective Equipment Protective Clothing
Protective Clothing (Flash Suit Cat. 4, 168J/cm2 or 40cal/cm2 *)

pants
* Incident energy at 1/10 of a second
jacket causing 2nd-degree burn to bare skin
underneath the PPE. Wear layers of
other cotton clothing underneath PPE
Flash Hood to reduce heat onto skin (but note that
this does not increase the arc flash
Safety Glasses rating of the PPE).
Hearing Protection
Safety Shoes
steel toed, leather upper
Electrical Hazard (EH shoes)
Rubber Gloves
class 2 / up to 17,500 VAC
leather gloves as “second layer”
to protect the rubber gloves

DANGER
don’t wear rings, watches etc.
”70% of people who survive a major arc flash event

have to receive long term counseling, almost 60%
of those same people will have failed marriages.“
Jim White, Shermco Industries Inc., in: Plant Engineering, April 2010

PPE – Personnel Protective Equipment Voltage Detector
Preferably use a type with

“narrow tip” to check the
voltage on individual cable.
typical medium
voltage cable:
conductor (Al, Cu)

conductive layer (XLPE) devices shown operate ”capacitive“
insulation (XLPE)
conductive layer The Voltage detector is used to verify that no voltage
(XLPE) is present on cables, terminals etc. (operating either
“on contact” or “capacitive”).
sheath
(Al, Cu) Voltage levels to check may be
protection Low Voltage
Medium Voltage.
XLPE:
cross linked Checking for medium voltage with a “capacitive” device,
low density use the “LV-setting” on the probe first to identify voltage
polyethylene
even from some distance.
Verifying the De-Energized Condition Voltage Detector
”on contact“
devices shown operate ”on contact“
test probe shown:

KP Test 5
1kV to 36kV, from 10% to 110% of rated voltage at 50Hz
acc. to EN50110-1, IEC61243-1:2003 and IEC61243-1:2005
Manufacturer:
Pfisterer Kontaktsysteme GmbH & Co KG
Rosenstraße 44
73650 Winterbach/Germany
www.pfisterer.de

Verifying the De-Energized Condition Voltage Measurement
Depending on local regulations the de-energized

condition might be allowed to be tested by
capacitive voltage detection devices (Tic Tracer)
or the use of a
device working “on contact”
might be mandatory.
YOU can do better:

• stand on the side of the door (not in front)
• use one hand only to hold the probe
test probe shown:

DSP3 HS5 or DSP3 HS11
Manufacturer: Rudolf Tietzsch
Willringhauser Straße 18
85256 Ennepetal/Germany
www.tietzsch.de
Basic rules for handling Voltage Detectors

- the Voltage Detector has to be selected for or set to the rated voltage to be checked
- the function of the Voltage Detector has to be checked on voltage before verifying the de-energized state
- the de-energized condition has to be checked on all three phases
- if possible, again check the function of the Voltage Detector on voltage
Personnel Safety in Switching Operations
“Disconnect”
(typically
no load isolator)
“Circuit Breaker”
(switches under load)
Any time you switch on the VFD or a Circuit Breaker a potential risk of malfunction is given.
For maximum safety, stand on the side and turn your head away.
(This precaution is strongly recommended when switching the device for the first time or after major repair work.)

Components carrying Medium Voltage ( > 1000 V )
Medium Voltage / voltage from the input line: 2.2 kVAC – 33.000 kVAC
Medium Voltage may be present at e.g.: input-, output terminals, cell connections, bus bars, transformer connections.
Components carrying Low Voltage ( < 1000 V )
Low Voltage
control power: 120, 240, 480, 575 VAC (230, 400 VAC)
customer input control: 120, 230 VAC / 24 VAC, VDC / 0-10 VDC / 4-20 mA
Hazardous Low Voltage (> 50 V) may be present at e.g.: contactors, miniature circuit breakers, power supplies,
terminals, transformers, control boards. Keep in mind to follow appropriate safety rules in Low Voltage circuits as well.

Medium Voltage Circuit Breaker (at Input of VFD)
HV circuit breaker MV circuit breaker
PH M
Hands OFF, other
Customer only ! load
Schematic of a Circuit Breaker Example of a Circuit Breaker

(racked out test position) (racked in operating position)
Medium Voltage Circuit Breaker
2 3
2
4
Stationary section Movable section (rear view) Movable section (front view)
(1) connection to common MV bus bar (1) to common MV bus bar (3) optional fuses
(2) connection to feeder (e.g.: VFD) (2) to feeder (e.g.: VFD) (4) vacuum contactors

Medium Voltage Circuit Breaker
Access to rack the Circuit Breaker in or out without opening the

front door of the Circuit Breaker compartment (with metering and
protection devices)
Movable section of Circuit Breaker (shown in operating position;

test position is given with the Circuit Breaker racked out to front)
Grounding the VFD and its Environment
HV circuit breaker MV circuit breaker
PH M
Hands OFF, other
Customer only ! load
Transformer Control Room VFD

(HV MV) M
Power Input,
Circuit Breaker
Earth Ground
Correct grounding of the VFD has to be verified.

The grounding is required for reasons of safety and to ensure correct operation of filtering and protection devices.

External Main Power Verification
Any work at the Medium Voltage sections of the VFD must be started only
after verification of the de-energized state of the external main power.
This rule applies both for the input power and for the motor connection.
The steps required and the sequence to follow depend on site conditions and
on the configuration of the VFD.
A choice of typical arrangements will be explained in the following in detail.
In general, the Five Safety Rules apply any time and have to be observed.
- Switch off the power supply on all poles
- Verify the de-energized condition
- Ensure against unauthorized re-energizing (lock-out, tag-out)
- Ground and short circuit the power terminals on all poles
- Cover or fence off adjacent live components
One Source of Isolation for the Medium Voltage
Step 1 Step 1 - the Vacuum Contactor must be

Vacuum location (room)
in the de-energized state;
Contactor other than VFD
Step 2 this is the dropped out position.
Step 2 - the Vacuum Contactor should then

be racked out (with door closed)
and locked in that position.
Step 3 Step 3 - verify that no power is present

at the VFD
Step 4 using an appropriate voltage tester, which
has been tested for functionality itself.
VFD
Step 4 - install grounding cables.
GND
GND

Two Sources of Isolation for the Medium Voltage
Step 1 - open Vacuum Contactor

Step 1 location (room)
Vacuum
Contactor other than VFD Step 2 - rack out the Vacuum Contactor and
Step 2
install lock on Vacuum Contactor
Step 3 - open Disconnect

+ through the viewing glass, verify
that contacts are open
Step 3
+ open the door and verify
viewing glass that no power is on the output
using an appropriate voltage tester, which
Disconnect has been tested for functionality itself.
+ install lock on Disconnect
Step 4 - verify that no power is present

Step 4
at the VFD
VFD using an appropriate voltage tester, which
Step 5 - for additional safety,

install grounding cables
Vacuum Contactor: - manual operation or
- remote control
Disconnect: - manual operation only
Isolating the Output (e.g. for Motors with long Lead Length)
As general rule the input has to be isolated and

grounded as per information on pages 22 or 23!
VFD VFD
Step 1a.1 - the Vacuum Contactor has to be
in the de-energized state;
Step 2 Step 3 this is the dropped out position.
Step 2
Step 3 Step 1a.2 - rack out the Vacuum Contactor
and lock it in that position.
Step 1a.1 Step 1b - open Disconnect, verify that contacts
Step 1a.2 Step 1b are open and lock it in that position
either or
(most have grounding connections)
Vacuum viewing glass
Contactor Step 2 - verify that no power is present

Disconnect
at the VFD motor terminals
using an appropriate voltage tester, which
Step 3 - install grounding cables at VFD

terminals T1, T2, T3 to ground.
Vacuum Contactor: - manual operation or

Motor Motor - remote control
Disconnect: - manual operation only

Isolating the Output (Motor with Bypass Capability)

VFD Step 1 - the Vacuum Contactor of the VFD

must be in the de-energized state;
this is the dropped out position.
Step 4 Step 3 Step 2 - rack out the Vacuum Contactor of

the VFD and lock it in that position.

Step 1 VFD Bypass
at the VFD.
Step 2 Vacuum Vacuum using an appropriate voltage tester, which
Contactor Contactor has been tested for functionality itself.
Step 4 - install grounding cables at VFD

terminals T1, T2, T3 to ground.
Motor
Isolating the Output (Motor with Parallel Drives)

VFD 1 VFD 2 Step 1 - the Vacuum Contactors of both VFDs

must be in the de-energized state;
this is the dropped out position.
Step 3
Step 4 Step 2 - rack out both Vacuum Contactors
and lock them in that position.

VFD 1 Step 1 VFD 2
at the output of either of the VFDs.
Vacuum Step 2 Vacuum using an appropriate voltage tester, which
Contactor Contactor has been tested for functionality itself.
Step 4 - install grounding cables at both VFDs

on terminals T1, T2, T3 to ground.
Motor

Parallel Drives on Synchronous Motor with Exciter
Power Grid 33.000 kV As general rule the input has to be isolated and
In this application the common field

supply is provided by connecting the
Exciter 1 VFD 1 VFD 2 Exciter 2 exciters in parallel with each other.
If even only one exciter contactor is
AC or DC
AC or DC
closed, power is present on the
Step Step Step Step output of each contactor.
5–8 1–4 1–4 5–8
To isolate both the stator terminals
VFD 1 (fed via VFDs) and the rotor
Exciter 1 VFD 2 Exciter 2 terminals (fed via exciters) of the
Contactor Vacuum Vacuum Contactor motor, proceed as follows:
Contactor Contactor
step 1 to 4
isolate both VFDs as shown on the
previous slide
step 5 to 8
isolate both exciter cabinets
(switch off, lock out/tag out, verify
power is off, ground)
Motor Field Supply
External Main Power Verification
Medium Voltage
Power has been removed on the input and isolated state has been verified
Wait 10 minutes for the system to discharge capacitors
If a cell is to be handled
verify that no input voltage is present on the cells
(various cell AC input voltages: 480, 630, 690, 750,1375, 600; measure phase-to-phase only)
verify that no voltage is present on the bus capacitors
(DC voltages as high as AC voltage x 1.413 can exist: 678, 890, 974, 1060, 1943, 930)
Control Voltage (two sources)

Verify that the voltmeter operates before shutting the control power off
Shut the control power (“disconnect”) off
Verify that power has been removed on all three phases on bottom side of “disconnect”
Shut the power off upstream of the drive
Verify that power has been removed on all three phases on top side of “disconnect”
Lock out and tag out both sources (in the drive / upstream of the drive)
Customer Input Control

Before removing or replacing boards
shut off the customer control input power to the boards
verify that power has been removed and is secure
Be cautious not to short input wires to the control boards

General Safety Precautions
Always turn the control power on before the medium voltage is applied!
Always turn the medium voltage off before shutting off the control power!
Never shut off the blower power and leave the main power on. This may cause the drive to
overheat and cause severe damage to the system.
Never run the drive with cabinet doors open. This reduces cooling to the drive.
Never connect or disconnect any meters, wiring or printed circuit boards while the drive
is energized.
Never store flammable material in, on or near the drive enclosure. This includes equipment
drawings and manuals.
Always be aware of electrostatic discharge (ESD) when working near or touching

components inside Drives.
(printed circuit boards contain components that are sensitive to static electricity.)
Mechanical Key Interlock (Standard)
INPUT MV POWER
KT 2
K2 K1 INPUT CIRCUIT BREAKER
K2
L
K2
Step 1 - de-energize the Medium Voltage

K2
Step 2 - remove K1
K1 Step 3 - insert K1 into KT2 assembly block
Step 4 - remove K2 keys and open cabinets
to be worked on
K2
Step 5 - verify in each cabinet that no voltage
DOOR INPUT SECTION 2
is present (AC or DC voltages)
K2
DOOR INPUT SECTION 3D KT 2 assembly block
K2 K2 K2 K2 K1
DOOR BYPASS SECTION 4B
K2
DOOR BYPASS SECTION 4D

Mechanical Key Interlock (System “Areva”)
Step 2 Step 4
Step 7
(3)
K2 K1
(1) K2
Step 5
K2 Step 6
K2
K1
Step 1 Step 3
33 kV VFD
switchgear Pre-charge Circuit Breaker (2)
Step 1 - disengage the 33 kV switchgear

Step 2 - take out the key (1) and insert it into the Areva key retention
Step 3 - disengage the vacuum contactor
Step 4 - take out the key (2) and insert it into the grounding assembly
Step 5 - engage the grounding system
Step 6 - take out the key (3) and insert it into the Areva key retention
Step 7 - take out key K1 and insert it into the VFD KT2 assembly block
Step 8 - remove K2 keys and open VFD cabinets to be worked on
Electromechanical Interlock
1 2
2 3
(1) “Dummy-Screw” to access the

Bolt of the Solenoid 4
(2) Interlocking Solenoid
(3) Cabinet Door Switch
(4) Control Section Door Switch
Door interlocking MUST NEVER be bypassed

with Medium Voltage switched on (C. B. = ON).
Perfect Harmony Drives manufactured in Nuernberg / Germany

feature an electromechanical interlocking as a standard.
To open any cabinet door of a Medium Voltage section, the
assigned solenoid (2) has to release the door mechanism by
being energized. The solenoid is energized with control voltage
1 available and the feedback signal “Circuit Breaker Open”.
If a door should be opened by force, the assigned cabinet door
switch (3) trips the Circuit Breaker.

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Automation and Drives

Medium Voltage Drives

04 Personal Safety page 1 © Siemens Industry 2013 - subject to modification

Automation and Drives

04 Personal Safety page 2 © Siemens Industry 2013 - subject to modification

Numerous exposed connections present lethal voltages.

Only qualified individuals should install, operate,

Verify that all power is off before you work on the

Never touch anything within the drive cabinets

Never assume that by switching off the circuit

Voltage is still present on the terminals of the input

04 Personal Safety page 3 © Siemens Industry 2013 - subject to modification

Automation and Drives

Always follow proper lock-out / tag-out procedures (lock-out / try-out)

04 Personal Safety page 4 © Siemens Industry 2013 - subject to modification

Electric Shock Hazards

Voltages may drive a current through your body.

04 Personal Safety page 5 © Siemens Industry 2013 - subject to modification

Automation and Drives

Arc Flash Hazards

Released arc flash energy causes following hazards to health or life:

04 Personal Safety page 6 © Siemens Industry 2013 - subject to modification

Areas and Boundaries

04 Personal Safety page 7 © Siemens Industry 2013 - subject to modification

Automation and Drives

Boundaries from NFPA70E

NFPA 70E 2012 Table 130.4(C)(a) shows

04 Personal Safety page 8 © Siemens Industry 2013 - subject to modification

PPE Levels (Personal Protection Equipment)

Hazard/ Clothing Description Required Minimum

Arc rated FR shirt and FR pants or FR

Arc Rated FR Shirt and FR pants or FR

Arc Rated FR Shirt and FR pants or FR

NFPA 70E 2012, table 130.7(C)(16)

04 Personal Safety page 9 © Siemens Industry 2013 - subject to modification

Automation and Drives

PPE – Personnel Protective Equipment Protective Clothing

Protective Clothing (Flash Suit Cat. 4, 168J/cm2 or 40cal/cm2 *)

Electrical Hazard (EH shoes)

leather gloves as “second layer”

to protect the rubber gloves

”70% of people who survive a major arc flash event

04 Personal Safety page 10 © Siemens Industry 2013 - subject to modification

PPE – Personnel Protective Equipment Voltage Detector

Preferably use a type with

conductor (Al, Cu)

04 Personal Safety page 11 © Siemens Industry 2013 - subject to modification

Automation and Drives

Verifying the De-Energized Condition Voltage Detector

devices shown operate ”on contact“

test probe shown:

04 Personal Safety page 12 © Siemens Industry 2013 - subject to modification

Verifying the De-Energized Condition Voltage Measurement

Depending on local regulations the de-energized

YOU can do better:

test probe shown:

Basic rules for handling Voltage Detectors

04 Personal Safety page 13 © Siemens Industry 2013 - subject to modification

Automation and Drives

Personnel Safety in Switching Operations

04 Personal Safety page 14 © Siemens Industry 2013 - subject to modification

Components carrying Medium Voltage ( > 1000 V )

04 Personal Safety page 15 © Siemens Industry 2013 - subject to modification