Electrical Safety

Policy Key Points

• Zero Energized Work Policy: Permit-Required energized electrical work is strictly prohibited for Yaskawa associates. Qualified associates may only work on or near exposed parts ≥50V for Product Testing, Voltage Measurement, and Troubleshooting.
• Verification of De-energization: All circuits are treated as ENERGIZED until verified dead using the 3-step voltmeter method (Test known source → Test equipment → Re-test known source).
• NFPA 70E 2024 Alignment: Mandatory arc flash/shock hazard assessments conducted every 5 years or upon installation; approach boundaries and arc ratings must be strictly observed.
• Qualified vs. Unqualified Status: Qualification is voltage- and location-specific (Low Voltage ≤1kV, Medium Voltage 1kV–35kV, High Voltage >35kV) and requires classroom/hands-on retraining every 3 years. Unqualified workers are strictly prohibited from entering restricted approach or arc flash boundaries.
• Cord & Equipment Safety: Extension cords and power strips must be 3-wire heavy-duty UL listed, directly connected to outlets (no daisy-chaining), and limited to 30 days of temporary use. Defective equipment must be tagged out and removed immediately.

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Policy

Introduction

Purpose of this Policy

To establish a program meeting or exceeding acceptable standards for electrical safety-related work practices. This program includes requirements for the comprehensive training of qualified and unqualified workers relating to: use of PPE, proper tool usage near electrical apparatus, testing procedures, working with specialized fixed equipment, understanding working clearances/approach boundaries, determining nominal voltages, and identifying exposed energized parts.

Safety-related work practices shall be employed to prevent electric shock or other injuries resulting from either direct or indirect electrical contact. Principal to this purpose is ensuring that only qualified personnel work on and near live electrical conductors and circuits.

Objectives of this Policy

The primary objective of this policy is to avoid injuries related to electrical contacts (shock, electrocution, arc flash/thermal burns, blast shrapnel, and secondary fall injuries). It provides guidance for determining required protection levels and documents training requirements for qualified and unqualified personnel in manufacturing, repair, facilities, labs, and offices.

Responsibilities

Yaskawa America, Inc.: Assure policy compliance, conduct annual policy reviews/revisions, and ensure training/retraining is provided.

Supervisors: Conduct periodic inspections to ensure safe work practices are followed; ensure protective equipment is available and tested as required.

Scope of this Policy

This policy affects all Yaskawa America, Inc. employees, contractors, and visitors across all facility operations.

References

OSHA 29 CFR 1910.331-360, NFPA 70E Standard (2024 Edition), Yaskawa Control of Hazardous Energy Policy.

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Definitions

Term	Definition	Visual Reference
Approach Distances	Must be established whenever work is conducted on electrical systems or components not in an electrically safe work condition.
Flash Protection Boundary	Distance beyond which appropriate flash protection equipment is required to prevent incurable 2nd-degree burns. May be inside or outside the limited approach boundary.
Limited Approach Boundary	Shock protection boundary designed to keep nonqualified persons at a safe distance from exposed electrical components.
Restricted Approach Boundary	Secondary shock protection boundary to prevent accidental contact with live parts. Qualified personnel only with proper PPE.
Arc Flash Hazard	Dangerous condition associated with energy release caused by an electric arc when conductors are exposed. Properly installed/maintained equipment poses minimal risk.
Arc Rating	Expressed in cal/cm², indicates level of arc flash protection provided by materials.
Barricade / Disconnecting Means	Barricades provide physical obstructions to prevent unauthorized access. Disconnecting means physically isolate circuits and must support LOTO.	—
Qualified / Unqualified Person	Qualified: Trained in electrical systems, hazard identification, and NFPA 70E (refreshed every 3 years). Unqualified: Prohibited from working near live conductors.	—
Energized / De-energized	All electrical equipment is treated as ENERGIZED until verified de-energized by qualified personnel using verified test instruments.	—

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Categories of Work

1. Normal Operation: Using grounded/double-insulated tools without live conductor exposure.

2. De-Energized Work: Work on verified dead conductors properly locked and tagged out.

3. Permit Required Work: Work within restricted boundaries at ≥50V. STRICTLY PROHIBITED for Yaskawa associates.

4. Non-Permit Required Work: Allowed for Qualified associates using safe work practices strictly for Product Testing, Voltage Measurement, or Troubleshooting.

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Normal Operation of Electrical Equipment

Minimal risk exists provided equipment is properly installed, maintained per manufacturer instructions, doors/covers are closed and secured with all hardware, and there is no evidence of impending failure (arching, overheating, loose parts, visible damage).

Electrical Equipment, Interlocks, and Housekeeping

Fixed Equipment: Installed only by Yaskawa-approved electrical contractors. Maintenance requires LOTO per Yaskawa policy. Verification of zero energy must precede work.

Portable Consumer & Industrial Products: Cords must be inspected prior to each shift/use for wire insulation damage. Damaged equipment must be removed from service immediately. Unplugging satisfies LOTO if plug remains in sole sight/control of worker.

Ladders: Must have non-conductive side-rails (fiberglass/wood) near exposed live parts.

Interlocks & Housekeeping: Interlocks may only be bypassed by qualified persons during active work and restored immediately after. Housekeeping must not occur within limited approach or arc flash boundaries.

Flexible Cord Sets (Extension Cords & Power Strips)

Must be 3-wire heavy-duty UL listed type, outdoor-rated if outside, and directly connected to a permanent wall receptacle (no series/daisy-chaining). Extension cords are limited to 30 days of temporary use and cannot run through walls, ceilings, floors, or doors.

Requirements for power strips include Surge/Spike Protectors and Portable Outlets.

Defective Equipment

Defective equipment must be tagged with "Out of Service" or "Do Not Use", removed from service, reported to management, and repaired only by competent authorities. Unrepairable equipment must be permanently destroyed.

De-Energized Work

Circuits must be locked and tagged out per Yaskawa LOTO policy. Circuits without LOTO are treated as energized. Qualified persons must test and visually inspect prior to work and warn personnel before re-energizing.

Work On or Near Exposed Energized Conductors

Permissible only for qualified workers performing Product Testing (Production, Repair, Field Service, Labs), Troubleshooting, Facilities Maintenance, or Voltage Measurement.

Qualified and Unqualified Workers

Qualified Workers: Must complete classroom and hands-on training covering equipment construction, hazard identification, approach distances, PPE selection, and test instrument limitations. Qualification is voltage-rated (Low ≤1kV, Medium 1kV–35kV, High >35kV) and must be refreshed every 3 years.

Unqualified Workers: Prohibited from entering the outer approach or arc flash boundary.

Host and Contract Employer Responsibilities

Yaskawa (Host) informs contractors of known site hazards and facility rules and reports violations. Contract Employers must instruct their personnel on communicated hazards, enforce Yaskawa rules, and report unique contractor hazards.

Test Instruments & 3-Step Voltage Verification

Test tools and leads must be visually inspected before every use and rated for the circuit voltage. When verifying zero voltage on circuits ≥50V, follow the mandatory 3-step test:

1.		While wearing appropriate PPE, verify voltmeter operation on a known energized source.
2.		While wearing appropriate PPE, test for voltage on all phase-to-phase and phase-to-ground points of target equipment.
3.		While wearing appropriate PPE, re-verify voltmeter operation on the known energized source to confirm meter functionality.

Approach Boundaries & Hazard Analysis

Outer boundaries require physical barricades/ribbon barriers or a dedicated attendant to warn unqualified personnel. Hazard analyses must be conducted every 5 years (or upon modification) per NFPA 70E 2024 to determine Arc Flash Boundaries, cal/cm² ratings, PPE levels, and Shock Boundaries.

PPE Categories & Standards

When arc rating is below 1.2 cal/cm², non-melting natural fiber clothing (≥4.5 oz/yd²), safety glasses, ear canal inserts, and leather/rubber insulating gloves are required.

All PPE must meet ANSI Z89.1 (Headwear), ANSI Z87.1 (Eye/Face), ASTM D120 (Rubber Gloves), ASTM F696 (Leather Protectors), and ASTM F2413 (Dielectric/Protective Footwear).

Other Precautions & Overhead Lines

Illness/fatigue impairment prohibits boundary entry. Blind reaching is forbidden. Conductive jewelry (watches, rings, metal glasses) must be removed. Minimum 10-foot clearance is required for overhead power lines ≤50kV.

Electrical Field Service

Field service personnel follow the most restrictive policy between Yaskawa and customer rules. Customer-led job briefings must precede all work.

Records

Record Title	Maintained by	Retention Time
Training: Electrical Safety-Related Work Practices	Associate Competency Record / Supervisor	Life of Employment
Training: NFPA 70E	Associate Competency Record / Supervisor	Life of Employment
Electrical Shock and Arc Flash Analysis	Equipment Cost Center Manager / Facilities	5 years (minimum)

Training Matrix

Training Title	Audience	Method	Refresher
General Electrical Safety Practices	All associates	Electronic / Classroom	Upon Policy Change
Unqualified Worker Practice & NFPA 70E Awareness	Unqualified near electrical areas	Electronic / Classroom	Min. every 3 years
Qualified Worker Practice & NFPA 70E Awareness	Qualified Associates	Classroom + Hands-On	Min. every 3 years

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Revision History

Rev #	Description	Release Date	Approved by
1	Conversion of old safety documents, rewrite, and issue	4/11/2016	Thurwanger
2	Updated NFPA 70E Tables	8/12/2019	Thurwanger
3	Added Work on or Near Overhead Lines (Including Buss Duct)	6/8/2023	Thurwanger
4	Changed reference of NFPA 70E 2015 version to NFPA 70E 2024 version	2/13/2026	Thurwanger

Program Review

Review Date	Reviewed by	Changes Required (Yes/No)	Revision # if updated
2/15/2017	Thurwanger	No	—
1/10/2018	Thurwanger	No	—
1/17/2019	Thurwanger	Yes	2
1/9/2020	Thurwanger	No	—
1/19/2021	Thurwanger	No	—
1/13/2022	Thurwanger	No	—
1/26/2023	Thurwanger	Yes	3
1/11/2024	Thurwanger	No	—
1/16/2025	Thurwanger	No	—
2/13/2026	Thurwanger	Yes	4