Is it OK to use a 240V connector body on a 480V line?
Is it OK to use a 240V connector body on a 480V line?
(OP)
I had the occasion recently to work with a 480V circuit. For a temporary hookup in a University environment, a prior visitor had installed a 240V 20A 3ph +ground female connector body [L15-20] on the 480V cord, which is switched at a fuse/ switch box nearby- perhaps 20 ft of cable. The unit tested draws only perhaps 5 amps. I changed the connector body to the proper L16-20 unit for 480V service, but then had to make an adapter in order to connect the cable into the facility's equipment for a very temporary and closely supervised test.
I was later instructed by my supervisor that the L16-20 connector body must be replaced with the incorrect but formerly installed 240V L15-20 connector body, so that the plug would be left interchangeable with the facility's equipment.
Under duress, this change was made, and the connector body and cable were annotated "480VAC". The facility operator was informed that I found this improper setup disturbing, because sooner or later someone is going to come along and plug a 240V machine into that L15 plug and apply 480V to it, resulting in damage and/or perhaps injury or death. I feel that this situation puts my company and myself at risk for liability for any such damage arising from this situation.
Because of personal interactions with my supervisors, who were present, I cannot bring up this issue with them. In fact, the whole company is not very receptive to constructive criticism.
What say you electrical experts?
No worries, it's a controlled environment?
Send a report to OSHA?
Report it to higher-ups in the company?
There are other safety issues in this environment too, but this seems the most egregious violation.
I was later instructed by my supervisor that the L16-20 connector body must be replaced with the incorrect but formerly installed 240V L15-20 connector body, so that the plug would be left interchangeable with the facility's equipment.
Under duress, this change was made, and the connector body and cable were annotated "480VAC". The facility operator was informed that I found this improper setup disturbing, because sooner or later someone is going to come along and plug a 240V machine into that L15 plug and apply 480V to it, resulting in damage and/or perhaps injury or death. I feel that this situation puts my company and myself at risk for liability for any such damage arising from this situation.
Because of personal interactions with my supervisors, who were present, I cannot bring up this issue with them. In fact, the whole company is not very receptive to constructive criticism.
What say you electrical experts?
No worries, it's a controlled environment?
Send a report to OSHA?
Report it to higher-ups in the company?
There are other safety issues in this environment too, but this seems the most egregious violation.






RE: Is it OK to use a 240V connector body on a 480V line?
RE: Is it OK to use a 240V connector body on a 480V line?
I cannot imagine why this isn't being corrected. Is someone being a stubborn moron, or do the bean counters think it will cost too much to retrofit the correct plugs? Let them know new plugs will cost less then the eventual electrical fire that will result.
Also let those involved that if an accident does happen, they may be liable for criminal negligence, as they knew of an unsafe situation and did nothing to correct it.
You are correct that eventually, someone will plug in a 240v load, and hopefully, the only thing that will happen is that the circuit protection will activate. We have different physical, incompatible plug types for different voltages for a reason. If this is a university environment, consider reporting it to health and safety. I'm sure they will have something to say about it.
Consider looking for a new job anyway. Do you really want to work for a bunch of people who:
A) Don't consider this a safety hazard.
B) Refuse to be talked to about this.
I'm sure there's more to this situation than the initial description. Please report back what happens.
-SceneryDriver
RE: Is it OK to use a 240V connector body on a 480V line?
So I can confirm someone will use that outlet sooner or later.
If you can't effectively reason with the responsible party based on the blatant safety hazard and the resulting liability both safety AND fire then you should seriously look for employment elsewhere, (while still employed of course). Once alternate employment is found write a letter to the administration explaining why you left who's responsible, who you spoke to, and who ordered you to return things to a hazardous state.
Keith Cress
kcress - http://www.flaminsystems.com
RE: Is it OK to use a 240V connector body on a 480V line?
I recently went to an OSHA presentation where this very issue came up.
WHEN someone gets hurt by this, and it WILL happen eventually, OSHA will get involved. If they do a thorough investigation and discover that YOU did it, they will want to know why. If you divulge that you had wanted to fix it correctly but was told to put it back to it's previous unsafe state, the supervisor who told you to do that can be held CRIMINALLY responsible, fined and JAILED by OSHA! They will not go after you as the worker (unless you purger yourself to try to defend one of those idiots). But they will question you with regards to your actions and if you come clean, they can and often will pursue the supervisors involved. And as of a couple of years ago, they are NO LONGER immune just because there is some vague corporate policy. OSHA requires them as supervisors to KNOW the rules, OBEY the rules, and ENFORCE the rules. Now it is a CRIME to not do so. There are of course no OSHA police, but there ARE prosecutors.
Then once the OSHA prosecutors get involved, the shark feeding frenzy begins (if it hadn't already)... Once that happens, a LOT of your personal time will get eaten up either defending yourself, or giving affidavits and/or testimony. It's a royal PITA.
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RE: Is it OK to use a 240V connector body on a 480V line?
Then start looking for a new job. It's unfortunate, but this is not something where you can be a "team player" and go along with acceptance of the hazard.
RE: Is it OK to use a 240V connector body on a 480V line?
This case is safety. Somebody might get hurt. Somebody might get more than hurt.
Best to you,
Goober Dave
Haven't see the forum policies? Do so now: Forum Policies
RE: Is it OK to use a 240V connector body on a 480V line?
RE: Is it OK to use a 240V connector body on a 480V line?
RE: Is it OK to use a 240V connector body on a 480V line?
RE: Is it OK to use a 240V connector body on a 480V line?
The case in question can happen when the installer of a 480V piece of equipment runs to the Home Depot and finds that they only have 240V plugs and receptacles. So, he snips the 480V plug off the plug-in equipment and puts his new 240V plug on. Then he wires the 240V receptacle to the incoming 480V circuit. We don't know how the OP's installation got to be like it is, so that's just a hypothetical scenario I just mentioned.
The danger is that the receptacle now says 240V on it. Somebody could come along with a 240V tool, maybe an air compressor or something, and plug it in without knowing that the supply is really 480V.
Best to you,
Goober Dave
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RE: Is it OK to use a 240V connector body on a 480V line?
Next time, leave the 480V receptacle (female end) and swap out the appliance plug with one of the proper rating/configuration.
There's a chance the equipment gets moved to other locations (all equipped with incorrect receptacles). But maybe not. And when you left the job site, everything worked correctly. And now you've created some more (billable) work when the equipment gets relocated and won't plug in.
RE: Is it OK to use a 240V connector body on a 480V line?
==============
I suspect my supervisor did that, to use the 480 thru the University's equipment w/o changing the University's cord ends.
the person doing the work couldn't be bothered to put on the correct plug.
===============
Oh, no, we HAVE enough of all these type plugs. That's not the issue. The issue is an "engineer" who thinks it's OK to leave an L15-20 connector body on a 480V cord.
Next time, leave the 480V receptacle (female end) and swap out the appliance plug with one of the proper rating/configuration.
============
I did that. I made an adapter WE can use to go from the proper 480V L16-20 connector body to the facility's L15-20 system. I was told in no uncertain terms to change that back, and NOT TO USE ADAPTERS ANYMORE. This is my direct supervisor.
The problem being, I cannot go to -his- supervisor ("S") with my concerns, and if I go higher up I fear that I will be shown the door. Then I lose my house and toys and all that. It's a hostile work environment. There is not one person in the company I would feel comfortable relating my concerns to. Until I have a job waiting.
"S" told me at that time to not bother taping the power and such cords to the floor. I was doing so because my wife tripped on a cord in her workplace and tore the rotator cuff in her shoulder, took almost a year to get back right, including about 6 months off work. I am the engineer who is the main schlepper/ worker and will be carrying parts and equipment over this cord for the entire week. It literally requires under 1 minute to tape 3 ft of cord down.... yet I get told not to bother, and chastised when I continue anyhow, after relating the reason why it is important.
Unfortunately, this job has some really great aspects as far as career satisfaction, and there is just nothing else engineering-wise available in the area... and I am deeply entrenched and to move would be quite a task.
RE: Is it OK to use a 240V connector body on a 480V line?
To me your choices are (a) live with the situation, assuming that the "great aspects" and monetary compensation outweigh the faults of the job, namely working in an environment where standards and safety are secondary to economy and expediency. (b)dig your heels in, state that if you are going to do the work that it will be done as you see fit, and hope that doing so does not result in your being told to draw your pay and depart the premises.
I'll take the liberty of guessing that you will go with (a), until a better job becomes available.
RE: Is it OK to use a 240V connector body on a 480V line?
Find out who the insurance carrier is for your place. They will be responsible for underwriting the fire AND personal liability of your organization. If it's a place like a university they will be VERY touchy about anything that can whip up a major liability like an electrocution or a fire in a multimillion dollar facility. Their entire focus is on "loss prevention" as that is where they make their money.
On a day off visit with them or their local representative. You don't need to tell them your name. Give them a false name, you can explain why you're using a false name - they will understand. That will even get their attention more focused.
Ask to speak with an accident investigator or a risk manager. Sit down and discuss with them your situation. Tell them about each thing you've seen - the wiring insanity, taping cords, etc. Request/suggest that they do a "facility inspection". Impress upon them that they not just "find" your issues but that they find several others before they find the issues you described.
They'll schedule a "loss prevention" inspection with your organization and do their thing. It will result in a list of things that "have to be addressed". Failure to correct the issues will result in a policy cancellation. This is serious stuff and will be given to your organization's administration. That will get things corrected and possibly even get some heads to roll, all while you remain back in the shadowy catacombs.
This will help your institution be a safer place.
Keith Cress
kcress - http://www.flaminsystems.com
RE: Is it OK to use a 240V connector body on a 480V line?
Best to you,
Goober Dave
Haven't see the forum policies? Do so now: Forum Policies
RE: Is it OK to use a 240V connector body on a 480V line?
The technical guys at insurance companies are smart and rather fun to talk to.
Do use a false name and tell them why.
Don't tell any of your coworkers about your plan.
Mike Halloran
Pembroke Pines, FL, USA