National Electric Code (NEC ) requires voltage drop to be no

more than 3% of source voltage.

Hazard - Inadequate Wiring

• Hazard - wire too small for the current

• Example - portable tool with an extension cord that has a wire too small for the tool– The tool will draw more current than the

cord can handle, causing overheating and a possible fire without tripping the circuit breaker

– The circuit breaker could be the right size for the circuit but not for the smaller-wire extension cord

Wire Gauge

WIRE

Wire gauge measures wires ranging in size from number 36 to 0 American wire gauge (AWG)

Percents as Fractions

3%

Equals

3/100

• “Percent” means “Per Hundred”

Percents to Fractions to Decimals

• 3%

• 3 / 100

• 0 . 0 3

• 3/100 means 3 divided by 100

• A short-cut when dividing by 100 is to move the decimal point two places to the left

3% of 120 volts

• 3% of 120 =

• 0.03 * 120 =

• 3.6 volts

• The word “of” indicates multiplication

3% of 240 volts

• 3% of 240 =

• 0.03 * 240 =

• 7.2 volts

• Remember…• 3% equals 0.03 • And• “of” means

multiplication

Control – Use the Correct Wire• Wire used depends on operation, building

materials, electrical load, and environmental factors• Use fixed cords rather than flexible cords• Use the correct extension cord

Must be 3-wire type and designed for hard or extra-hard use

Hazard – Defective Cords & Wires

• Plastic or rubber covering is missing

• Damaged extension cords & tools

Hazard – Damaged Cords

• Cords can be damaged by:– Aging– Door or window edges– Staples or fastenings– Abrasion from adjacent

materials– Activity in the area

• Improper use can cause shocks, burns or fire

Control – Cords & Wires• Insulate live wires • Check before use• Use only cords that are 3-wire type • Use only cords marked for hard or

extra-hard usage• Use only cords, connection devices,

and fittings equipped with strain relief

• Remove cords by pulling on the plugs, not the cords

• Cords not marked for hard or extra-hard use, or which have been modified, must be taken out of service immediately

Permissible Use of Flexible Cords

Stationary equipment-to facilitate interchange

DO NOT use flexible wiring where frequent inspection would be difficult or where damage would be likely.

Flexible cords must not be . . .• run through holes in walls,

ceilings, or floors;• run through doorways, windows,

or similar openings (unless physically protected);

• hidden in walls, ceilings, floors, conduit or other raceways.

Grounding Grounding creates a low-

resistance path from a tool to the earth to disperse unwanted current.

When a short or lightning

occurs, energy flows to the ground, protecting you from electrical shock, injury and death.

Hazard – Improper Grounding

• Tools plugged into improperly grounded circuits may become energized

• Broken wire or plug on extension cord

• Some of the most frequently violated OSHA standards

Control – Ground Tools & Equipment

• Ground power supply systems, electrical circuits, and electrical equipment

• Frequently inspect electrical systems to insure path to ground is continuous

• Inspect electrical equipment before use

• Don’t remove ground prongs from tools or extension cords

• Ground exposed metal parts of equipment

Voltage Drop FormulaK = constant

12 ohms is the constant for copper that is 0.001 mil thick at 86˚F

I = Current Flow in amps

L = Length of Wire in feet

ACM= Circular Mil Area in Circular Mils

CMdrop A

KILVoltage 2

Wire Gauge & CMAGauge (AWG or kcmil)• 18

• 16

• 14

• 12

• 10

• 8

Circular Mil Area• 1620

• 2580

• 4110

• 6530

• 10380

• 16510

Using Voltage Drop Formula

Problem:

There is an extension cord that measures 25 ft. and has a current draw of 5 amps. If the cord is 18 gauge, what is the voltage drop?

What We Know:

CMdrop A

KILVoltage 2

K = 12 ohms

I = 5 amps

L = 25 ft

CMA = 1620 CM (refer to previous table)

Using Voltage Drop Formula

voltsVoltage drop 85.116203000

• State the formula

• Plug in the known values

• Calculate

• Check for acceptability – since 1.85 volts is less than 3.6, this is acceptable for 120 volt circuit

CM

ftampsVoltage drop 1620255122

CMdrop A

KILVoltage 2

Using Voltage Drop Formula

Problem #2:There is an extension cord that measures 150 ft. and has a current draw of 5 amps. If the cord is 18 gauge, what is the voltage drop?

What We Know:

CMdrop A

KILVoltage 2

K = 12

I = 5 amps

L = 150 ft

CMA = 1620 CM (refer to previous table)

Using Voltage Drop Formula

CMdrop A

KILVoltage 2

voltsVoltage drop 1.11162018000

• State the Formula

• Plug in the known values

• Calculate

• Check for acceptability – since 11.1 volts is greater than 3.6, this is NOT acceptable for 120 volt circuit

CM

ftampsohmsVoltagedrop 16201505122

• We can solve our Voltage Drop Formula to find the necessary and Circular Mil Area and determine the proper wire gauge.

• In our previous problem, the voltage drop is greater than 3%, it is a code violation.

Using Voltage Drop Formula

Solving Voltage Drop Formula

CMdrop A

KILVoltage 2

drop

CMVoltage

KILA 2

• State the Formula

• This is a Proportion, so we can cross multiply

• Cross Multiply

• Solve for CMA (Isolating the Variable)

CM

drop

AKILVoltage 2

1

KILVoltageA dropCM 2

Solving for CMA

Remember the Problem:There is an extension cord that measures 150 ft. and has a current draw of 5 amps. If the cord is 18 gauge, what is the voltage drop?

What We Know:

K = 12

I = 5 amps

L = 150 ft

voltsVoltage drop 6.3

drop

CMVoltage

KILA 2

Solving for CMA

drop

CMVoltage

KILA 2

CMACM 50006.3

18000

• State the Formula

• Plug in the known values

• Calculate

• Check for gauge (referring to previous table) – since 5000 is between 4110 and 6530, we need to go with 6530, which

coordinates with a 12 gauge wire.

volts

ftampsohmsACM6.3

1505122

Control - Electrical Protective Devices

• Automatically opens circuit if excess current from overload or ground-fault is detected – shutting off electricity

• Includes GFCI’s, fuses, and circuit breakers

• Fuses and circuit breakers are overcurrent devices. When too much current:

Fuses melt Circuit breakers trip open

Hazard – Overloaded CircuitsHazards may result from:• Too many devices plugged

into a circuit, causing heated wires and possibly a fire

• Damaged tools overheating• Lack of overcurrent

protection• Wire insulation melting,

which may cause arcing and a fire in the area where the overload exists, even inside a wall

Control – Use GFCI (ground-fault circuit interrupter)

• Protects you from shock• Detects difference in current

between the black and white wires

• If ground fault detected, GFCI shuts off electricity in 1/40th of a second

• Use GFCI’s on all 120-volt, single-phase, 15- and 20-ampere receptacles, or have an assured equipment grounding conductor program.

Power Tool Requirements• Have a three-wire cord with

ground plugged into a grounded receptacle, or

• Be double insulated, or• Be powered by a low-voltage

isolation transformer

Tool Safety Tips

• Use gloves and appropriate footwear• Store in dry place when not using• Don’t use in wet/damp conditions • Keep working areas well lit• Ensure not a tripping hazard• Don’t carry a tool by the cord• Don’t yank the cord to disconnect it • Keep cords away from heat, oil, & sharp

edges• Disconnect when not in use and when

changing accessories such as blades & bits • Remove damaged tools from use

Summary – Hazards & ProtectionsHazardsInadequate wiringExposed electrical partsWires with bad insulationUngrounded electrical systems and toolsOverloaded circuitsDamaged power tools and equipmentUsing the wrong PPE and toolsOverhead powerlinesAll hazards are made worse in wet conditions

Protective MeasuresProper groundingUse GFCI’sUse fuses and circuit breakersGuard live partsLockout/TagoutProper use of flexible cordsClose electric panelsTraining