Module 6:

Solar electrical safety

Working on or near electricity can be v ery dangerous. The term electrocution refers to death
from electrical shock. Electrocution is the third -leading cause of work-related deaths among
1 6- and 1 7 -year-olds. Electrocution is the cause of 1 2% of all workplace deaths among young
workers.
This solar electrical safety module helps you understand hazards and develop a plan for
working safely around solar electric sy stems.

Module Contents
Ev aluate and identify solar electrical safety hazards.....................................................93
General electrical hazards.................................................................................... 93
Ev aluate your electrical hazards ........................................................................... 95
Understanding potential injuries from solar electric hazards ..................................95
Practices for working safely with solar electric systems ................................................96
Working with power tools and electric cords .........................................................97
Working with electrical circuits............................................................................97
Working with solar electric sy stems......................................................................98
Working with batteries ......................................................................................1 00
Working smart .................................................................................................1 00
Recovering from electrical accidents ........................................................................ 1 01
What to do ....................................................................................................... 1 01
Rev iew quiz: Solar electrical safety ...........................................................................1 02

Solar Construction Safety – 12/06 91

 Learning objectives
T his solar electrical safety m odule presents:
 The hazards associated with electricity.
 How to work safely with electricity.
 Recov ering from electrical-related accidents.

Whenev er y ou work with power tools or electrical circuits there are safety risks from electrical
shock.
Electrical shock occurs when y ou complete a path for current to flow through y our body. The
risk of shock is alway s present in live electrical circuits. Since electric current will take the path
of least resistance to ground, if y ou contact a liv e circuit and complete a path to ground or to
another circuit, y ou will get shocked.
Shocks can be minor resulting in a v ery sharp pain. Shocks can also cause serious injury or
death. Getting shocked can also lead to falls from ro oftops or ladders, leading to fall related
injuries. Although, in general, the higher the v oltage the higher the risk, it’s possible that
electric currents of as little as 1 00mA can induce v entricular fibrillation, disrupting your
heart’s normal blood pumping operation, resulting in conv ulsions and possibly death. In
comparison, a ty pical house electrical service of 1 20vAC can produce currents thousands of
times higher than 1 00mA.
As with other workplace hazards, use this process to minimize electrical haza rds:
1. Ev aluate and identify electrical hazards.
2. Eliminate or remov e electrical hazards.
3. Control electrical hazards that cannot be eliminated.
4. Recov er from accidents.

Solar Construction Safety – 12/06 92

 Evaluate and identify solar electrical safety hazards

Identify ing electrical-related safety hazards in y our job helps y ou determine how to eliminate
or control them before they cause injuries. The following section describes important factors
to consider in conducting an ev aluation and defining actions to address solar electric hazards
at y our work site.
Solar electric systems present the unique condition of hav ing two electrical power sources in
the home or business. Electrical power comes from both the utility and from the solar
electrical system. Pulling the main breaker will shut down the utility power but will not shut
off a solar electric array. This is a new consideration for many electricians and must be
understood while working on electrical sy stems that use solar energy .
Both electric shock and arc -flash are potential hazards that must be protected against when
working on solar electric photov oltaic (PV ) sy stems.
NOTE: Some common myths claim that AC (alternating current) is more dangerous than DC
(direct current) or v ice v ersa. Neither myth is true because both AC and DC currents present
significant safety hazards. The truth is that electrical current can kill – whether it is DC or AC.
They are both dangerous sources of current and both should be treated with the same safety
practices.

General electrical hazards

 Ov erhead power lines.

Ov erhead power lines are not
Employ ers must not allow their
insulated – they can and do kill
workers to work near any part of an
people that contact them. More than
electrical circuit UNLESS the
half of all electrocutions are caused
by direct worker contact with circuit is de-energized (shut off)
energized power lines. When cranes, and grounded, or guarded in such a
work platforms, or other conductive way that it cannot be contacted.
materials such as ladders or  Ground-fault protection
aluminum mounting rails contact must be prov ided at
ov erhead wires, the equipment construction sites to guard
operator or other workers can be against electrical shock.
killed. If y ou do not maintain
required clearance distances from
power lines, y ou can be shocked and
killed. Y ou must always stay a minimum of 1 0 feet away from overhead power lines! (The
minimum distance for v oltages up to 50kV is 1 0 feet. For v oltages over 50kV, the
minimum distance is 1 0 feet plus 4 inches for every 1 0 kV over 50kV.)
 Electrical systems and tools that are not grounded or double-insulated.
The most common OSHA electrical v iolation is improper grounding of equipment and
circuitry. The metal parts of an electrical wiring sy stem that are exposed (switch plates,
ceiling light fix tures, conduit, etc.) should be grounded and at zero v olts. If the sy stem is
not grounded properly, these parts may become energized. Metal parts of motors,
appliances, or electronics that are plugged into improperly grounded circuits may be
energized. When a circuit is not grounded properly, a hazard exists because unwanted

Solar Construction Safety – 12/06 93

 v oltage cannot be safely eliminated. If there is no safe path to ground for fault currents,
ex posed metal parts in damaged appliances can become energized.
Ex tension cords with missing or broken ground terminals are unsafe and should never be
used. If y ou contact a defective electrical device that is not grounded (or is grounded
improperly), and y ou complete a path to ground, y ou will be shocked.
 Ov erloaded circuits.
Ov erloads in an electrical sy stem are hazardous because they can produce heat or arcing.

A ground fault circ uit interrupter, or GFCI, is an inex pensive

lifesav er. GFCIs detect any difference in electrical current
between the two circuit wires. This difference in current could
happen when electrical equipment is not working correctly,
causing leakage current. If leakage current (a ground fault) is
detected in a GFCI-protected circuit, the GFCI switches off the
current in the circuit, protecting y ou from a dangerous shock.
GFCIs are set at about 5 mA and are designed to protect workers
from electrocution. GFCIs also detect the loss of current resulting
from leakage through a person who is beginning to be shocked. If
this situation occurs, the GFCI switches off the current in the
circuit. GFCIs are different from circuit breakers because they
detect leakage currents rather than ov erloads. Circuits with
missing, damaged, or improperly wired GFCIs may allow y ou to be
shocked.

Wires and other components in an electrical system or circuit have a max imum amount
of current they can carry safely .
If too many devices are plugged into a circuit, or if a single dev ice draws too much current,
or if incorrect wire size is used, the electrical current can heat the wires to a v ery high
temperature. Ex cessive heat can melt insulation and lead to arcing which can create ground
faults or fires.
In order to prevent too much current in a circuit, a circuit breaker or fuse is placed in the
circuit. Breakers and fuses do the same thing: open the circuit to shut off the electrical
current. If the breakers or fuses are too big for the wir es they are supposed to protect, an
ov erload in the circuit will not be detected and the current will not be shut off.
 Ladders that conduct electricity .
 Do not use metal ladders near electrical circuits or lines. Instead, use ladders made of
fiberglass.
 Beware of ov erhead power lines when y ou work with ladders and scaffolding.
 If y ou receive a shock while on a ladder or scaffolding—even a mild one—you may
lose y our balance and fall, which can result in injury or death.
 Electrical hazards can be m ade worse if the worker, location, or equipment
is wet.
Y ou don’t have to be standing in water to be electrocuted. Wet clothing, high humidity, and
perspiration also increase y our chances of being electrocuted.
Working in wet conditions is hazardous because it increases the chance of completing a
path for current flow. If y ou touch a liv e wire or other electrical component—and you are
well-grounded because y ou are standing in a wet area —y ou will receiv e a shock.

Solar Construction Safety – 12/06 94

 Evaluate your electrical hazards
It’s important to ev aluate each specific situation to dev elop a list of hazards and potential
injuries that could occur at y our work site. Understanding hazards and potential injuries,
along with knowing the likelihood of an accident occurring, enables you to s et up a suitable
safety policy for each specific job. This ev aluation will help y ou set up policy and procedures
to reduce the risks associated with electricity and energized equipment.
The following ex amples demonstrate work conditions that construction c rews face while
working with solar electric systems. You may come up with additional situations in y our job
that need to be addressed. You are encouraged to use these common ex amples but to analyze
y our own situation as well.
Electrical hazards in construc tion work situations can include:
 Using power tools and electric cords.
 Working with ex isting and new wiring and circuits.
 Working with solar electric PV panels, batteries, and equipment.
Once y ou’ve gone through y our work situation related to electricity and energized equipment,
y ou need to identify the hazards and risks associated with those situations. Then decide what
action is needed to address the hazard.
1. Using power tools and electric cords.
a. Working conditions include: using power tools and ex tension cords.
b. Hazards include: using non-GFCI power cords, un-grounded power tools, and frayed
or improperly spliced electric cords resulting in injuries associated with electric shock.
 Action: Dev elop policies and procedures for using power tools and electric cords.

2. Working with ex isting and new wiring and circuits.

a. Working conditions include: working on DC and AC wiring, connecting to utility .
b. Hazards include: ex posure to live electric circuits or energized equipment resulting in
injuries associated with electric shock and arc-flash.
 Action: Dev elop policies and procedures working with new and ex isting electric circuits.

3. Working with solar electric PV panels, batteries, and equipment.

a.Working conditions include: wiring and connecting PV array s, installing and
removing batteries, and working with inv erters and balance of sy stem equipment.
b. Hazards include: mov ing and installing PV panels, working with inv erters and
balance of sy stem equipment resulting in injuries associated with electric shock and
arc-flash.
 Action: Dev elop safe practices for working with solar electric sy stems.
 Action: Dev elop safe practices installing, handling, and disposing of batteries.

The actions listed abov e will be addressed in the ‘Work Safely ’ section that follows the
understanding injuries section below.

Understanding potential injuries from solar electric hazards

Electrical injuries can include the following:

Solar Construction Safety – 12/06 95

  Electrocution (death due to electrical shock).
 Electrical shock causing:
 Sev ere burns.
 Conv ulsions leading to v entricular fibrillation and internal or fall -related injury .
 Numbness, tingling, paraly sis.
 V ision, hearing, or speech problems.

Practices for working safely with solar electric systems

The prev ious section described how to identify jobsite hazards using an ex ample to ev aluate
potential risk areas for ty pical solar construction work related to solar electric systems. Now
it’s time to dev elop a strategy to reduce these risks.
This section helps y ou develop strategies to either eliminate or control the hazards in the
action items noted in the previous section. Since many construction hazards are difficult to
eliminate altogether, most of the suggestions deal with controlling the hazard by developing
safe work practices and habits. However, y ou should always be on the lookout for ways to
eliminate hazards altogether.
The following actions were identified in the prev ious section:
 Action 1 : Dev elop policies and procedures for using power tools and electric cords.
 Action 2: Dev elop policies and procedures working with new and ex isting electric circuits.
 Action 3: Dev elop safe practices for working with solar electric sy stems.
 Action 4: Dev elop safe practices installing, handling, and disposing of batteries.

The following sections help y ou dev elop plans to reduce hazards while:
1. Working with power tools and electric cords.
2. Working with electrical circuits.
3. Working with solar electric sy stems.
4. Working with batteries.

OAR 437 -003-0404, Branch Circ uits, requires ground-fault circuit interrupters
(GFCIs) on all 1 25 -volt, single-phase, 1 5-, 20-, and 30-ampere receptacles that are
not part of the permanent wiring of a building or structure. If a permanently wired
receptacle (not equipped with GFCI protection) is used for temporary electric power
in a construction project, GFCI protection must be provided at the user end.
Portable plug-in and cord-type GFCIs are probably the most practical devices for
construction workers who use cord sets for temporary power when there is no
protection at the source.

Solar Construction Safety – 12/06 96

 Working with power tools and electric cords
Companies working with power tools and electric cords must create clear safety policies for the
maintenance and use of this equipment. Following are some areas to consider when setting
power tool and electric cord safety practices and policies.
 Ground Fault Circuit Interrupters (GFCI or GFI) sav e liv es.
 Know and understand OSHA rules on GFCI dev ices. See Oregon OSHA information
box on GFCI requirements.
 Ensure all ex tension cords and equipment are protected by GFCI. Follow
manufacturers testing procedures to insure the device is working properly.
 Alway s use GFCI protected ex tension cords and equipment on the job.
 Construction equipment is used in rugged env ironments – equipment inspections can
help ensure equipment is maintained in safe working condition.
 Electric equipment and power cords should always be inspected after an accident or
damage occurs.
 Power cords with ground prongs missing should nev er be used.
 V isually inspect electrical equipment prior to every use for electrical hazards such as
missing prongs, fray ed cords, cracked tool cases etc. Remove from service and apply a
warning tag to any tools that are damaged.

Working with electrical circuits

Prev enting electric shock by working on de -energized circuits is a key to electric safety.
Following are some items to consider when working on electric circuits.
 Alway s de-energize circuits before beginning work on them.
 Y ou can’t get shocked by a de-energized circuit. Unfortunately, many electric
accidents have been caused by assumed ‘dead’ circuits. Working safely on circuits
includes testing them for hazardous energy prior to working on them.
 Use a meter or circuit test device such as a current clamp to ensure the circuit is dead
prior to working on it.

Safety T ip: V erify that y our meter is operating properly on a liv e

circuit to ensure it is working. This ensures that y ou have the meter
leads in the proper terminals, the meter settings properly set, and that
y our meter is operating correctly.
Make sure that y ou’re meter is properly set to check for AC or DC
v oltage depending on the circuit y ou are working on.
When checking for a circuit under load a current clamp is a safer device
to use than a ty pical multi-meter – current clamps do not require you to
break the circuit and thus limit an arc-flash hazard.

Solar Construction Safety – 12/06 97

  Implement circuit lock and tag out rules
 Lock out the power on sy stems that are capable o f being locked out. Remember that
the lock out tag is not for the person that y ou are aware of and that knows y ou are
working on the electrical circuit – it’s for the person y ou don’t know and that doesn’t
know y ou are working on the circuit. Y ou must notify all affected persons.
 Tag out all circuits that you’re working on at points where that equipment or circuit
can be energized.

Working with solar electric systems

Electricians are familiar with electricity coming from the utility side of the meter. With solar
electric systems there are 2 sources of electricity : the utility and the solar electric sy stem.
Turning off the main breaker doesn’t stop a solar electric system from hav ing the capacity to
produce power. Electricians are used to isolating the ‘load’ from the power source (usually
with a breaker or other disconnect switch) and then they proceed to work on that ‘safed zero
energy load’. With a solar electric system y ou work on the power source itself (the PV panels
or associated wiring) – this is fundamentally different than working on a ‘safed load’ and you
must keep this in mind. Ev en low light conditions can create a v oltage potential that can lead
to a shock or arc -flash. A surprise shock delivered at the wrong time could cause a fall from a
roof or ladder.
 Follow the procedures listed in the prev ious section on working with electrical sy stems
 Note that PV inv erters may have significant capacitors that could hold a charge after
the power source is removed – alway s follow manufacturer’s directions and check the
equipment y ou are working on for specific operation and safety information.
 The only method of ‘turning off’ a solar array is removing the ‘fuel’ source – the sun. If
needed, cover the array with an opaque cover that blocks sunlight to prevent a solar panel
from generating electricity .
 Small amounts of sunlight can produce a v oltage potential and shock or arc -flash hazard
 V oltages can be present even in v ery low light conditions. While these voltages may
not be enough to operate the inv erter, the potential v oltages are enough to produce a
shock to an unsuspecting installer. Surprise shocks can cause injuries directly or
cause a fall from a roo f or ladder.
 Prior to working on a string of solar PV panels, if y ou’re going to be connecting or
disconnecting circuits, y ou should disrupt the current path by disconnecting the DC
Disconnect switch. Tag and lock out the circuit using standard procedures discussed
in the prev ious section.
 Grid tied solar sy stems hav e 2 energy sources to consider
 Shutting off the main circuit breaker does not affect the potential output of a solar PV
array – ev en if the inv erter shuts off.
It’s important to remember that opening (turning off) the main breaker does not
shut off the power source from the solar array . Wires from the PV side of the

Solar Construction Safety – 12/06 98

 circuit can still have a v oltage potential that can deliver significant current even
in low light conditions.
 Disconnect switches can isolate the solar PV array but they do not shut the power off.
Remember that if y ou open the DC disconnect switch, the line from the solar PV
array can still have v oltage potential on it. This is similar to the voltage potential
present on the utility side of the line after the main breaker is opened. Treat the
wiring coming from the solar PV array with the same caution y ou treat the utility
power line. A residential PV array can hav e up to 600 V DC potential.
 An electric arc -flash hazard ex ists while adding or remov ing a series of solar PV panels
 NEV ER disconnect PV module
connectors or other associated PV
wiring under load!
 While adding or removing a series of
solar PV panels, if a path for current
is completed or the string was under
load, an electrical arc can occur
across the wire junction. The energy
from the bright arc -flash can cause
sev ere burns. Another hazard is the
surprise arc blast causing you to lose
balance and fall off a roof or ladder.
 Alway s open the DC Disconnect
Switch prior to working on a solar PV
sy stem.

 Use a current clamp to check for

hazardous energy prior to working
on a PV array .

Solar Construction Safety – 12/06 99

 Working with batteries
Working with battery back-up sy stems can be the most dangerous part of solar electric
installations and maintenance. Batteries can be dangerous!
Make sure all employ ees working with batteries understand the dangers and safety codes
relev ant to battery sy stems.
 Refer to NEC and manufacturing guidelines for issues pertaining to proper handling,
installation, and disposal of batteries.
 Ty pical batteries are lead acid. Both lead and acid are harmful chemicals. Lead is known
to cause reproductiv e harm and acid can cause sev ere burns.
 Care should alway s be taken to prevent arcing at or near battery terminals. Always open
the Main DC disconnect switch between the batteries and the inv erter prior to servicing
or working on the battery bank.
 Battery banks can store voltages with v ery high current potential. These higher potentials
can create electrical arc hazards. Metal tools and personal jewelry can create arcing on
batteries that lead to severe burns or battery explosions. Remove personal jewelry and use
only appropriate tools when working on batteries.
 When working on batteries it is recommended that ey e protection be worn.
 Dead batteries are considered hazardous and must be recy cled properly .

Working smart
Controlling contact with electrical v oltages and the currents they can cause helps y ou create a
safe work env ironment. In addition to preventing shocks, a safe work environment reduces the
chance of fires, burns, and falls.
Make y our solar electric construction env ironment safer by :
 Prev ent shocking currents from electrical sy stems and tools by grounding them.
 Prev ent potential hazardous currents by using GFCIs.
 Work with a “buddy .”
Do not work alone. Both of y ou should be trained in CPR. Both of y ou must know what to
do in an emergency .
 Plan to lock out and tag out circuits and equipment.
Before work is done on a circuit, shut off the circuit, lock and tag out the circuit at the
distribution panel, then test the circuit to make sure it is de -energized.
Working on energized (“hot”) circuits is one of the most dangerous things any worker
could do. If someone turns on a circuit without warning, you can be shocked, burned, or
electrocuted. The unex pected starting of electrical equipment can cause severe injury or
death.
 Remov e jewelry and metal objects.
Remov e jewelry and other metal objects or apparel from y our body before beginning work.
These can cause burns if worn near high currents and can get caught as y ou work.

Solar Construction Safety – 12/06 10

0
 Recovering from electrical accidents
Solar contractors sometimes work with small crews in isolated jobsites. Because electrical
accidents can cause incapacitating injuries, it is crucial to hav e a plan to deal with
emergencies.
Emergency planning protects lives, equipment, and property. By planning for emergencies you
can increase y our ability to act properly to av oid further injury. Do not wait for an emergency
to start thinking about how to respond. It is difficult to think clearly during an emergency;
training can increase the chances of a proper response.

What to do
1. Shut off the power supply if the v ictim is still in contact with the energized circuit.
2. While y ou do this, hav e someone else call for help.
3. Do not touch the v ictim y ourself if he or she is still in contact with a liv e electrical circuit.
If y ou cannot shut sy stem power off quickly , pry ing someone away from a liv e circuit
should only be done with a non-conductive item such as a dry board. Be especially careful
if the area is wet.
4. Do not leav e the v ictim unless there is absolutely no other option. You should stay with the
v ictim while Emergency Medical Services (EMS) is contacted by someone else. If the victim
is not breathing, does not hav e a heartbeat, or is badly injured, quick response by a team
of EMTs or paramedics giv es the best chance for surv iv al.
5. Administer first aid and CPR if required and
y ou’re trained. If y ou are not trained in CPR or
first aid, now is the time to get trained—before
y ou find y ourself in this situation! Ask your
instructor or supervisor how y ou can become
certified in CPR.

Safety T ip: Learn first

aid and CPR now!

Solar Construction Safety – 12/06 10

1
 Review quiz: Solar electrical safety
The following questions and true or false statements will help to ensure y ou understand the
material presented in this module. Please print y our name, sign and date the rev iew whe n you
are finished.
1. What are the three things to know the location of to be prepared for an emergency ?

2. Ov erhead powerlines are dangerous and can kill. (T or F)

3. Solar PV panels can product electric current with v ery little sunlight or other light source.
(T or F)

4. What is the minimum distance to stay away from ov erhead powerlines?

5. AC current is more dangerous than DC. (T or F)

6. DC current is more dangerous than AC. (T or F)

7 . GFCI is required for contractors unless y ou are using ex tension cords. (T or F)

8. Working around electrical circuits when wet is more dangerous than when dry . (T or F)

Demonstrate the following to the trainer:

 Describe the company ’s GFCI policy
 Describe the company ’s lock out / tag out policy
 Properly use a multi-meter and current clamp to check a circuit prior to working on it

Training subject Date Location

I have received training on the above subject and completed the Review quiz. This training has provided me adequate
opportunity to ask questions and learn safety guidelines to determine and correct skill deficiencies. I understand that
using these guidelines and procedures safely is a condition of em ployment. I fully intend to com ply with all safety and
operational guidelines discussed. I understand t hat failure to com ply with these guidelines m ay result in progressive
discipline (or correctiv e actions) up to and including term ination.

Em ploy ee nam e Signature Date

I have conducted training to the individual listed above. I have explained related procedures, practices, and policies.
The em ployee was given the opportunity to ask questions and practice procedures taught under my supervision. Based
on the em ployee’s performance, I have determined that the employee has adequate knowledge and skills to safely
perform these procedures and practices.

Trainer nam e Signature Date

Solar Construction Safety – 12/06 10

2
Solar Construction Safety – 12/06 10
3