2.11 Turn low voltage, then high voltage disconnect switches into the “ON” position.

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LABOUR ESTIMATE
Operation
1

MSD remove and replace

Men

Hours

2

2.67

Labour Time
M X HR
5.34

PARTS REQUIRED
Item

Part Number

1

806450

RCPT-MNL SVCE DISC 220 AMP

Qty.
per
Coach
2

2

805480

PLUG-MNL SVCE DISC 250 AMP

2

EA

3

853309

POWERBAR-ESS TO MSD

4

EA

4

852861

BRACKET-DISCONNECT SWITCH MTG

2

EA

Description

Units

Notes

EA

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Appendix A – NFIL Spec 532295 - High
Voltage Safety Guidelines & Procedures for
New Flyer Battery Bus
The following provides general guidelines in relation to safety and best practices
when completing installation or servicing work on any New Flyer battery bus
vehicle platform.
This document is not meant to supersede the actual released installation and
assembly drawings and where conflicts arise, the released engineering drawings
take precedence.

Introduction
The utmost concern, while working with High Voltage (HV) systems, is the safety of yourself, other
personnel and the potential of damage to property. To minimize these risks, it is crucial to be
properly trained and always maintain a very alert, questioning and disciplined attitude without fail.
As soon as your guard is lowered, then the potential of an accident is probable that can hurt or kill
yourself or someone else and possibly damage property.
What is High Voltage (HV)?
Any form of voltage that is greater than 50 volts if the person’s skin at the electrical contact points
is not compromised and not wet.

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Equipment Required
The following equipment shall be required:
Digital Multimeter (DMM), 1000 volt Category III, 600 volt Category IV,
10Megohm impedance or greater with insulated case or rubber holster
Clamp-on current probe, 1000 volt Category III, 600 volt Category IV
High Pot Tester (Hi-Pot)
Phase rotation meter
Personal Protection Equipment (PPE) appropriate for 700volt DC & 230
volt AC with Class 00 or higher HV gloves with compatible leather over
gloves. Appropriate safety glasses as well as the face shield. The PPE
shall also meet the required Arc Flash & Arc Blast requirements. Before
use, inspect the PPE in accordance with this guideline.
Adequate lighting
HV insulated mat
Two fused HV clip leads 10 inches long
Safety barricade with warning lights & "Danger High Voltage" signs
Belt tool pouch (use only to carry small components up/down a ladder)
Torque Screwdriver set
Imperial torque nut driver set
Metric torque nut driver set
Imperial 1/4" torque drive socket set
Imperial 3/8" torque drive socket set
Insulated rescue hook
ABC Fire extinguisher, 5 lb minimum, at the activity areas
Spare HV and low voltage fuses
Equipment Calibration
All test equipment must be within their calibration interval and recorded such with the respective
serial numbers. These records must be available to the Checker.
Personnel Requirement
Only trained personnel shall supervise and perform High Voltage system testing, checkout and
troubleshooting. Two personnel (one called the Checker & the other called Monitor/Recorder) shall
perform Checkout Procedures, together, to ensure safety of themselves, others nearby & for the
protection of vehicle & property. Refresher training shall be provided to these personnel on a
regular basis and when new systems are to be checked by them. The training of the personnel
shall consist of:
HV & low voltage basics, intermediate & advanced electricity
HV & low voltage electrical systems of the vehicle
Shop safety practices & procedures
First aide including CPR & the use of the shop defibrillator
How to release a victim that can’t let go HV
Quickest method of shutting down HV
Fire fighting and emergency procedures

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HV & arcflash safety
Organized & tidy placement of equipment & tools allowing for
unrestricted movement
Operation of Hi-pot
Operation of Phase Rotation Meter
To ensure effectiveness of training, exams of the trained material shall be required with a high
passing mark of at least 80% and a retraining of the missed 20 % on a one to one basis.
Checker Function
(Caution: The Checker must not have any health conditions that can be exacerbated when startled and must
not have any electronic implants.)
Directed by the Monitor/Recorder
Performs all preparations & checks
Wears PPE as specified by the Checkout Procedure
Performs all restorations
Vehicle Inspection
It is necessary that the vehicle to be checked out, first be visually inspected of all systems,
workmanship and with special attention to ensuring there is no HV cable or equipment damage or
chafing.
High Voltage Checkout Preparation
(1)
The scope of the work must be accurately defined such as a Checkout Procedure
that requires systematic steps with sign offs. Before a Checkout is performed, the
Supervisor, Checker and Monitor/Recorder must conduct a briefing of what shall
transpire, identify potential hazards, resist pressures of “is it done yet?”, anticipate
problems and question possible events. If an unexpected electrical hazard or fault
occurs, during any time of the Checkout, it must be immediately reported to the
supervisor. After the Checkout is completed the same group should review the
results and processes and make proposed modifications to the procedures if
required.
(2)
Install Safety barricade with warning lights & signs indicating "Danger High Voltage"
around the vehicle perimeter and ensure no personnel are within the fenced
perimeter during the checkout procedure.
(3)
It shall always be the goal to check the systems as much as possible with all HV
power OFF and Locked Out/Tagged Out and proven as de-energized by voltage
measurement using the DMM. The functionality of the DMM must be proved before
and after the verification of no HV present. Then, if possible, the HV systems should
be challenged by trying to energize them while checking that no HV appears.
(4)
When it is necessary to perform tests of HV systems with the power ON, then the
Working Live procedure must be followed.
(5)
The test personnel shall always rehearse the actions required in case of any
possible accident scenarios.

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(6)

Before beginning the Checkout Procedure, the test personnel shall remove all their
jewelry (including pierced ones), watches and any electrically conductive objects on
them.

PPE Requirements
The PPE voltage class, Arc Flash and Arc Blast rating shall be compatible with the voltage and Arc
Flash capability of the systems being tested. Appropriate leather glove protectors shall be worn
over the HV rubber gloves.
PPE Care & Testing
Rubber insulated PPE shall be periodically cleaned and tested in accordance with 29 CFR
1910.137 and the appropriate ANSI/ASTM standards. HV gloves, sleeves and mats shall be tested
every 6 months. PPE apparel shall be cleaned and maintained in accordance with the
manufacturer’s instructions. A record of the PPE testing shall be maintained and available to the
users.
PPE Inspection
Inspect PPE equipment, before use, for any degradation or damage and ensure that the HV gloves
have been tested every 6 months. Also perform an air pressure test on the HV gloves before and
after each use. If during PPE use a potential damaging incident occurred to the PPE, stop further
testing and inspect the PPE. If at any time the PPE is defective, reject it, and obtain an accepted
one.
PPE Storage
PPE apparel should be stored lying flat, undistorted, right-side out and not folded in protective
containers. The HV mats can be rolled with an inside diameter greater than 2 inches.
Rubber HV gloves should be stored in cool, dark, dry, and free from damaging chemicals or
vapors. The glove cuffs should face downwards, without folding, in the appropriate glove bag and
hung vertically.
Insulated Tools
Insulated tools should be visually inspected for insulation damage before and after each session of
use.
Lockout/Tagout Procedure
The Lockout/Tagout procedure should be followed that is specified in the respective Checkout
procedure. When removing the lock and tag:
(1)

The locks and tags shall be removed by the installer of them or under her/his
supervision.

(2)

If the installer of the locks and tags is not available, then her/his supervisor:
(a) Ensures that the installer of the locks and tags in not in the facility
(b) Contacts the installer to inform her/him that the locks and tags will be removed
(c) Reminds the installer of the lock and tag removal when she/he resumes work

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Stored Energy
Personnel must always remember the characteristics of stored energy devices such as capacitors
and batteries and when energy is available from.
Working Live
To maximize safety, it is always important to perform the maximum amount of HV checkout in the
de-energized state.
When it is necessary to work with HV equipment while energized or to verify whether HV is
present, the utmost care and safety procedures must be utilized including:
(1)
Wearing appropriate PPE with protector gloves over top of the HV rubber gloves
(2)
Ensure all personnel, except the Checker and Monitor/Recorder, are clear of the
vehicle
(3)
Kneeling or standing on HV insulated mat
Energizing & De-energizing Procedure
It is critical that before any HV system is energized that a visual check be performed to ensure that
all possible HV compartments are closed and there is no debris, tools or test equipment lying on
HV terminations. If there is a certain sequence of energizing and de-energizing the HV system,
then all personnel involved must be trained in this sequence. (CAUTION: Never try to connect or
disconnect circuit components such as cables, fuses, connectors, etc while there is current flowing
in the circuit.)
Electrical Injuries
Electrical injuries should be immediately reported to the first aide personnel and the supervisor. Other than
electrostatic shocks, even non-injurious electrical shocks should be reported to the supervisor. These should
be immediately investigated and documented to determine the cause and prevent the occurrence in the future.

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Appendix B – NFIL PPE Categories

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Appendix C – Live Work Permit

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