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Occupational Safety & Health and Electrical/Environmental Laws (Industrial Safety & Health Act, Electrical Facility Standards, Grounding, PSE, PRTR Act)

Electrical Equipment Assembly – Control Panels 電気機器組立て (Grade 2 theory) · 技能検定「電気機器組立て」2級 学科(配電盤・制御盤組立て) · Written by Tokutei Pass based on the official study texts; not copied verbatim.

Illuminance Standards in the Ordinance on Industrial Safety and Health (Precision 300lx, Ordinary 150lx, Rough 70lx), Work Environment, 5S, and KY

Regarding the "illuminance (brightness: unit is lux - lx)" on work surfaces in workplaces where workers are regularly employed, the Ordinance on Industrial Safety and Health stipulates the following 3 minimum threshold levels according to the category of work:

① "Precision work": "300 lux (lx) or more", ② "Ordinary work": "150 lux (lx) or more", ③ "Rough work": "70 lux (lx) or more" (even after recent regulatory amendments, written exams continue to test the numerical values of these traditional 3 categories).

Written exams frequently feature number-swapping traps such as "300 lux or more for ordinary work (false: precision work is ≥ 300 lx, while ordinary work is ≥ 150 lx)" or "500 lux or more for precision work (false)", so memorize these exact numbers carefully.

Furthermore, natural and artificial lighting must follow "a method that avoids extreme contrast between light and dark and does not cause glare", indoor workspace air volume must be at least 10 m³ per worker, and indoor passageways must be at least 80 cm wide and kept free of obstacles.

In addition, workplaces must thoroughly implement the foundational "5S (Sort - Seiri, Set in Order - Seiton, Shine - Seisou, Standardize - Seiketsu, Sustain - Shitsuke)", check work procedure manuals before starting work, and practice "KY (Kiken Yochi / Hazard Prediction) activities" with Pointing and Calling (Shisa Koshou) as well as "Hiyari-Hatto (near-miss) reporting".

Key points


  • Work surface illuminance standards are "Precision work: 300 lx or more", "Ordinary work: 150 lx or more", and "Rough work: 70 lx or more"

  • Lighting must avoid extreme light-dark contrast and prevent glare, and indoor passageways must maintain a width of 80 cm or more

  • Prevent industrial accidents proactively through 5S (Sort, Set in Order, Shine, Standardize, Sustain) and pre-work "KY (Hazard Prediction) activities"
WordMeaning
Work surface illuminance standards (300lx, 150lx, 70lx)
Prevention of extreme contrast and glare
5S (Sort, Set in Order, Shine, Standardize, Sustain)
KY (Hazard Prediction) activities and Pointing-and-Calling (Shisa Koshou)

Drilling Machine Safety (Prohibition of Gloves with Rotating Drills, Use of Vise) and Grinder Safety (Trial Run, Protective Gear)

When operating machinery with rotating cutting tools or workpieces such as a "drilling machine (drill press)" or "lathe / milling machine" used to drill holes in control panel enclosures or mounting plates in electrical equipment assembly, the law "strictly prohibits allowing workers to wear gloves (such as cotton work gloves)".

This is because if glove fibers catch on a rotating drill bit or spindle, the worker's fingers and hand will be entangled and pulled in instantaneously, causing a severe injury (if a written exam statement says "wear cotton gloves for safety during drilling machine work", it is always false).

Furthermore, when drilling holes in a small workpiece on a drilling machine, to prevent the workpiece from spinning violently with the drill at the moment of breakthrough and injuring the hand, never hold the workpiece directly by hand; always clamp it securely to the table using a "machine vise or clamp".

When removing cutting chips (swarf), never brush them away with bare hands or blow them with your mouth; always stop the machine first, use a "brush or dedicated hook", and wear "safety glasses" to protect your eyes from flying chips.

Meanwhile, when using a "grinder (grinding wheel)", perform a trial run for "1 minute or more" before starting work each day and for "3 minutes or more" when a grinding wheel has been replaced, install a protective wheel guard, adjust the gap between the wheel and the work rest to "3 mm or less", and wear safety glasses.

Key points


  • When working with rotating cutting tools (drill bits) such as on a drilling machine or lathe, "wearing gloves (cotton work gloves) is prohibited" to prevent entanglement

  • Never hold a workpiece by hand when drilling; always secure it with a "vise or clamp", and remove chips with a brush after stopping the machine

  • Grinding wheels (grinders) require a trial run of "1 minute or more" before daily work and "3 minutes or more" upon wheel replacement, along with wearing safety glasses
WordMeaning
Prohibition of wearing gloves (drilling machines, rotating machinery)
Securing workpieces with a machine vise
Grinding wheel trial run (1 min before work, 3 min upon replacement)
Safety glasses and dust respirator

Crane & Slinging (Tamagake) Safety (Skill Training Course for ≥ 1t, Single Designated Signaler, Safety Factor ≥ 6, Sling Angle ≤ 60°)

When lifting large switchboards, transformers, or motors with a crane, "slinging work (Tamagake)" — attaching and detaching wire ropes or lifting chains to/from the load — for a crane with a lifting capacity of "1 ton (t) or more" may only be performed by someone who has completed the "Slinging Skill Training Course (Tamagake Ginou Koushuu)" (under 1t requires special education).

Regarding crane operation, a lifting capacity of 5t or more requires a Crane/Derrick Operator License, and under 5t requires special education (for floor-operated cranes that move with the load and have a capacity of 5t or more, completion of the Floor-Operated Crane Operation Skill Training Course is required).

When a crane operator and slinging workers work together, the employer must "designate 1 work leader (or 1 person to give signals)", and only that designated person may give consistent, clear signals (the statement "all workers freely give signals on their own" is a critical error).

The "safety factor (breaking load ÷ maximum applied load)" of wire ropes used for slinging must be "6 or more" (5 or more for lifting chains and hooks); wire ropes with broken elemental wires (10% or more in one lay), diameter reduction (exceeding 7% of nominal diameter), kinks (twisting loops), or severe deformation/corrosion are prohibited from use.

Furthermore, when slinging a load with 2 or more wire ropes, because rope tension increases sharply as the sling angle widens, in principle keep the "sling angle within 60°", first lift the load just a few dozen centimeters off the floor ("lift-off check / Chigiri") to verify the center of gravity and slinging condition, and never allow anyone to enter beneath a suspended load.

Crane & Slinging (Tamagake) Safety (Skill Training Course for ≥ 1t, Single Designated Signaler, Safety Factor ≥ 6, Sling Angle ≤ 60°)

Key points


  • Slinging (Tamagake) work for cranes with a lifting capacity of "1t or more" requires qualification from completing the "Slinging Skill Training Course"

  • Crane operation signals must be given solely by "1 fixed signaler designated in advance" (arbitrary signaling by multiple people is strictly prohibited)

  • Slinging wire ropes must have a safety factor of "6 or more", a basic sling angle "within 60°", and ropes with kinks or broken wires must not be used
WordMeaning
Slinging Skill Training Course / Tamagake (lifting capacity ≥ 1t)
Unified signaling by a single designated signaler
Wire rope safety factor (≥ 6) and kink defects
Sling angle (within 60°) and lift-off check (Chigiri)

Electric Shock Prevention (Current Through Body & Hazard Levels), Special Education for Electrical Work, and De-energized Work Procedure

The danger level of an electric shock to the human body is determined by the "magnitude of current" passing through the body, the "duration of current flow", and the path (whether it passes through the heart). At commercial AC frequency, about 1mA causes a tingling sensation (perception current), and exceeding about 10–15mA causes muscle spasms that prevent letting go of the wire voluntarily (let-go current).

Furthermore, if a current of "approximately 50mA (50–100mA) or more" flows near the heart, it causes "ventricular fibrillation (loss of the heart's pumping function)", leading to death within a short time. When skin is wet with sweat or water, human body resistance drops drastically from several thousand Ω to a few hundred Ω, making even 100V low voltage fatal.

When assigning workers to install, inspect, repair, or operate live low-voltage or high-voltage circuits (including operating switches inside control panels and conducting dielectric withstand voltage tests), the employer must provide "Special Education for Electrical Handling Work".

Inspection and repair of electrical equipment must in principle be performed as "de-energized work (power-off state)" following this strict sequence: ① Open switches (breakers, disconnectors) to cut off power, ② "Lock (Lockout)" the switches and post "Work in Progress - Do Not Energize warning tags (Tagout)" to prevent accidental re-closing by third parties.

③ Use a "voltage detector (checked for proper function before use)" to "verify zero voltage" at the work point and discharge residual charge in power capacitors, ④ On high-voltage circuits, attach "short-circuit grounding gear" (when attaching, connect the "ground side first, line side second"; when removing, reverse the order: "line side first, ground side second").

Key points


  • Current of about 10–15mA or more through the body prevents voluntary release, and about 50mA or more causes fatal "ventricular fibrillation"

  • Inspecting or operating live electrical circuits requires "Special Education for Low/High-Voltage Electrical Handling Work"

  • For de-energized work, strictly follow: "Cut power → Lock switch & post warning tag → Verify zero voltage with detector & discharge residual charge → Attach short-circuit grounding"
WordMeaning
Let-go current and ventricular fibrillation (approx. 50mA)
Special Education for Electrical Handling Work
Lockout / Tagout (locking switches and posting warning tags)
Voltage detection and short-circuit grounding gear (ground side connected first)

Voltage Classifications in Technical Standards for Electrical Facilities (Low Voltage: DC ≤ 750V, AC ≤ 600V) and Insulation Resistance Standards

In the "Ministerial Ordinance Establishing Technical Standards for Electrical Facilities", voltage is classified into 3 categories: "Low Voltage, High Voltage, and Extra-High Voltage (Special High Voltage)". ① "Low Voltage" is "750 V or less for direct current (DC), and 600 V or less for alternating current (AC)".

② "High Voltage" exceeds low voltage (over 750 V DC, over 600 V AC) up to "7000 V or less", and ③ "Extra-High Voltage" is "over 7000 V". It is important to note that the upper limit of low voltage differs between direct current (750V) and alternating current (600V).

Furthermore, the "insulation resistance value (between conductors and between conductors and ground)" of low-voltage indoor circuits must be at or above the following values according to the operating voltage category of the circuit:

① Voltage to ground of 150 V or less (such as single-phase 100V circuits or grounded single-phase 100/200V circuits): "0.1 MΩ or more", ② Voltage to ground over 150 V up to operating voltage of 300 V or less (such as ungrounded 200V circuits): "0.2 MΩ or more", ③ Operating voltage over 300 V low voltage (such as three-phase 400V power circuits): "0.4 MΩ or more".

Additionally, to prevent electric shock accidents, low-voltage electrical machinery/apparatus with metal enclosures or portable/moveable equipment exceeding 150V to ground, or low-voltage circuits in damp/wet locations, are legally required to be equipped with an "earth leakage circuit breaker (ELCB)" that automatically cuts off the circuit upon a ground fault.

Key points


  • Voltage classifications are "Low Voltage: DC ≤ 750V, AC ≤ 600V", "High Voltage: ≤ 7000V", and "Extra-High Voltage: over 7000V"

  • Low-voltage circuit insulation resistance standards are: "0.1 MΩ or more" for ≤ 150V to ground, "0.2 MΩ or more" for ≤ 300V, and "0.4 MΩ or more" for over 300V

  • Installing an "earth leakage circuit breaker (ELCB)" is mandatory for metal-enclosed low-voltage apparatus (over 150V to ground) or circuits in wet locations
WordMeaning
3 voltage classifications (Low Voltage, High Voltage, Extra-High Voltage)
Low-voltage insulation resistance standards (0.1, 0.2, 0.4 MΩ)
Voltage to ground (in grounded circuits)
Mandatory installation of earth leakage circuit breakers (ELCB)

4 Types of Grounding Work (Class A, B, C, D), Minimum Ground Wire Diameter (1.6mm), and Instrument Transformer Secondary Grounding

In the Interpretation of Technical Standards for Electrical Facilities, "grounding work (earthing)" to prevent electric shock, fire, and high-voltage contact faults is divided into 4 classes: "Class A, Class B, Class C, and Class D". Metal enclosures and iron frames of low-voltage apparatus with an operating voltage of "300 V or less" require "Class D grounding work (ground resistance ≤ 100 Ω)".

Enclosures of low-voltage apparatus with an operating voltage "exceeding 300 V" (such as three-phase 400V motors or control panels) require "Class C grounding work (ground resistance ≤ 10 Ω)" (however, if an earth leakage breaker operating within 0.5 seconds is installed, both Class C and Class D are relaxed to ≤ 500 Ω).

Furthermore, enclosures and frames of high-voltage or extra-high-voltage apparatus require "Class A grounding work (ground resistance ≤ 10 Ω)", while the low-voltage neutral point (or 1 terminal) of a transformer coupling high/extra-high voltage with low voltage requires "Class B grounding work" to prevent low-voltage potential rise during inter-winding contact.

Two topics tested extremely often on the written exam are the "minimum diameter of a solid ground wire" and the "grounding class of the secondary side of instrument transformers (VT, CT)". ① Ground wires for "Class C and Class D grounding work" must safely carry fault currents and use an "annealed copper wire with a diameter of 1.6 mm or more" (Class A requires ≥ 2.6 mm diameter, Class B in principle ≥ 4.0 mm).

② Moreover, to prevent high voltage from entering meters or protective relays upon insulation breakdown, "the secondary circuit of a High-Voltage instrument transformer (VT, CT) requires 'Class D grounding work'", whereas "the secondary circuit of an Extra-High-Voltage instrument transformer requires 'Class A grounding work'".

4 Types of Grounding Work (Class A, B, C, D), Minimum Ground Wire Diameter (1.6mm), and Instrument Transformer Secondary Grounding

Key points


  • Enclosures of low-voltage apparatus ≤ 300V use "Class D grounding (≤ 100Ω)", > 300V use "Class C grounding (≤ 10Ω)", and high-voltage enclosures use "Class A grounding (≤ 10Ω)"

  • Ground wires for Class C and Class D grounding work must use "annealed copper wire of 1.6 mm diameter or more" (Class A uses 2.6 mm diameter or more)

  • Apply "Class D grounding work to the secondary circuit of High-Voltage instrument transformers (VT/CT)", and "Class A grounding work to the secondary of Extra-High-Voltage instrument transformers"
WordMeaning
Class A, Class B, Class C, and Class D grounding work
Minimum diameter of Class C & D ground wire (1.6mm annealed copper wire)
High-voltage instrument transformer secondary grounding (Class D)
Relaxation when combined with an earth leakage breaker (≤ 500Ω)

Electrical Appliance and Material Safety Act (Diamond PSE for Specified Appliances, Round PSE), Fire Service Act, and Electrical Fire Extinguishing

Under the "Electrical Appliance and Material Safety Act (PSE Law)", which regulates the safety of electrical products and components used in general electrical installations, regulated items are classified into "Specified Electrical Appliances and Materials" and "Electrical Appliances and Materials other than Specified ones", and compliant products must display the "PSE mark".

"Specified Electrical Appliances and Materials (such as 600V vinyl insulated wire IV, molded case circuit breakers, earth leakage circuit breakers, thermal fuses, etc.)", which pose a particularly high risk of hazard or fault due to their structure or usage, require conformity inspection by a registered inspection body and display "PSE inside a diamond-shaped frame".

Conversely, "Electrical Appliances and Materials other than Specified ones (such as ventilating fans, fluorescent/LED lamps, small single-phase transformers, etc.)" display "PSE inside a round (circular) frame" (distinguishing between the diamond PSE mark and round PSE mark is tested on the written exam).

Furthermore, most organic solvents and mineral oils used as cleaning agents, paint thinners, or insulating oils in factories fall under "Hazardous Materials Category 4 (Flammable Liquids)" under the "Fire Service Act"; storing or handling the designated quantity or more requires assigning a licensed Hazardous Materials Engineer in an approved facility, strictly prohibiting open flames, and preventing static electricity.

In addition, for an "electrical fire (Class C fire)" involving energized switchboards or transformers, spraying water, foam, or loaded stream (solid stream) extinguishers will conduct electricity through the extinguishing agent and cause "electric shock", so never use them; first cut off the power supply, then use a "dry chemical powder (ABC) extinguisher" or "carbon dioxide (CO2) extinguisher".

Key points


  • Under the Electrical Appliance and Material Safety Act, "Specified Electrical Appliances" display the "diamond-shaped PSE mark", while other regulated appliances display the "round PSE mark"

  • Cleaning organic solvents and insulating oils fall under "Category 4 Hazardous Materials (Flammable Liquids)" of the Fire Service Act, requiring strict fire prohibition and ventilation

  • Using water or foam extinguishers on an energized "electrical fire (Class C fire)" causes electric shock; cut power first and use a "dry powder (ABC) extinguisher" or "CO2 extinguisher"
WordMeaning
Specified Electrical Appliances and the diamond PSE mark
Non-Specified Electrical Appliances and the round PSE mark
Fire Service Act Category 4 Hazardous Materials (flammable liquids)
Extinguishing methods for electrical fires (Class C fires: powder, CO2)

PRTR Act (Chemical Release Management: Designated Substances and Exemption of Solid Products), RoHS Directive, and Organic Solvents

The "Act on Confirmation, etc. of Release Amounts of Specific Chemical Substances in the Environment and Promotion of Improvements to the Management Thereof (PRTR Act)" mandates reporting environmental release and transfer amounts (PRTR system) and providing a "Safety Data Sheet (SDS)" for "Class I Designated Chemical Substances" that may be harmful to the environment or human health.

There are 2 top-priority points tested almost every year on the written exam: ① Regarding regulated substances, "lead and its compounds" (contained in leaded solder, etc.), "hexavalent chromium compounds" (related to plating and rustproofing), and "cadmium compounds" are designated as "Specific Class I Designated Chemical Substances (Class I Designated Chemical Substances)".

(Therefore, any exam choice claiming that "lead compounds are excluded from designated chemical substances" or "hexavalent chromium is exempt" is false).

② Conversely, even if the chemical content ratio exceeds the threshold, "solid articles (products)" whose shape is already fixed and which do not involve melting, evaporation, dissolution, or dust generation from grinding/cutting during handling — such as "chrome-plated screws, metal plates, pipes, or finished parts used for electrical equipment assembly" — are "excluded (exempt)" from PRTR handling volume calculation and reporting requirements.

Additionally, the international "RoHS Directive" restricting hazardous substances in electrical and electronic equipment restricts the use of "lead, mercury, cadmium, hexavalent chromium, PBB, PBDE, and phthalates"; and when using cleaning "organic solvents" inside a factory, operate local exhaust ventilation and wear an organic gas respirator.

Key points


  • Under the PRTR Act, "lead compounds" and "hexavalent chromium compounds" are regulated as Class I Designated Chemical Substances

  • Solid finished parts used as-is in electrical equipment assembly, such as "chrome-plated screws" (solid articles not involving melting or dust generation), are exempt from PRTR reporting

  • When transferring or supplying regulated chemical substances, provide an "SDS (Safety Data Sheet)" detailing hazard information, and manage substances restricted under the RoHS Directive
WordMeaning
PRTR Act and Class I Designated Chemical Substances
Exemption rule for solid products (such as chrome-plated screws)
SDS (Safety Data Sheet)
RoHS Directive and Ordinance on Prevention of Organic Solvent Poisoning

Safety, Regulations & Electrical Standards

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