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LH edited this page Apr 11, 2024 · 6 revisions

Risks

  • Mains Voltage Electrocution
  • Fire

AC kills you, fire kills your family.

Please ask for someone's help, if it's outside of your comfort zone. They will probably be glad to do so rather than you risking your life.

Guidelines

Always

  • Keep the AC side isolated from physical access
  • Never work on the AC side without unplugging the power cable
  • Keep a fire extinguisher on hand
  • Turn power off and don't hot plug jumpers or cables
  • Do not leave your printer unattended for long periods of time
  • Let someone know you are printing, have a camera, VPN access and a backup system such as a smart smoke alarm connected to a remote relay
  • Don't be ignorant

Research

  • Know the power usage of your components
  • Research your cable wire ratings and ampacity
  • Check your connector and crimps maximum ratings
  • Check the circuit amperage and heat ratings of your PCBs
  • Check the current ratings of your MOSFETs and SSRs
  • Rate DC AC fuses to ~125% of your maximum usage
  • Choose Flame-Retardant materials for your enclosures

Safety Systems

  • Test how your system's design prevents or mitigates unsafe consequences of the system's failure
  • Think of how the system will react to fast or slow failures
    • A slow discharged short though a resistance which won't trip fuses
    • MOSFETS and SSRs failing in a closed circuit causing a thermal runaway
    • Short circuits on high voltage sources
    • Accumulated heat on improper connectors with high resistance
    • Software safety systems freezing or becoming offline

General Tips

  • Do not insert tinned wire into screw down terminals. Crimp ferules or twist the bare copper wires.
  • Do not leave any AC bare wires exposed
  • Do not insert ferules or tinned wires into WAGO type connectors
  • Check your spade connectors fitting tightness and check the surrounding temperatures after a couple of minutes of operation
  • Ensure that cables are secured with strain reliefs
  • Ensure that appropriate cables and are chosen for motion applications
  • Look for points of potential wear and drag fatigue damage

Material hazards

  • Cutting, drilling, or sanding carbon fiber or glass fiber has to be done in a well ventilated space and wearing a respirator mask. Wetting the surface helps to minimize the airborne particles.
  • Please research the safety recommendations regarding processing carbon fiber, or other composite materials.

Note: These are common sense tips based on my personal experience, and are not coming from an authorized professional.

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