Key Questions to Ask When Ordering circuit breaker lock out

Electrical Lockout tagout is a safety procedure used when work needs to be done on electrical wiring or equipment. Of course the circuit breaker needs to be shut off first. But what if someone turns the breaker on while work on the wiring is still in progress? The purpose of a lockout tagout device is to prevent that from happening. All lockout tagouts have some things in common. The lockout is installed and a lock is placed on it. Only the electrician doing the work should have the key. A tagout is then placed onto the lock to notify everyone that work on circuit wiring is being done. The tag warns them not to tamper with the device. The tag should have the date and contact information of the electrician performing the work.

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Every electrician must use some lockout tagout device when working on live circuit wiring. OSHA mandates the use of lockout tagout. Electrical Lockout tagout can save lives

– The Panel Lockout is much sturdier and secure than those small, red, circuit breaker lockouts, which can fall off or easily be removed.

-Many different size circuit breaker lockouts are needed to fit different types and sizes of circuit breakers. The Panel Lockout can be used any type or size breaker. It can be installed on any panel cover with screws. In addition, with our clips, the Panel Lockout can be installed on most panel covers without screws.

-The panel door can not be closed when circuit breaker lockouts are installed. Unauthorized personnel will have access to all the unprotected breakers in the panel. The door is always closed and locked with the Panel Lockout.

-Several circuit breakers are easily be locked out with the Panel Lockout with only one padlock.

-When installing a circuit breaker lockout there is a danger of accidentally tripping an adjacent breaker. The Panel Lockout is installed outside the panel so there is no chance of accidentally disturbing an active circuit breaker.

Aside from its use as a lockout tagout device, the Panel Lockout is also a time saving tool in new construction. During construction, we often wait until the last minute to terminate wiring onto live panels in order to keep the wires to the field dead as long as possible. Panel trims and covers aren’t installed until the wires are terminated. With the Panel Lockout, as soon as all the wires are installed they can be terminated.  Then the panel trims and covers can be installed and all the circuit breakers can be locked out with the Panel Lockout. It eliminates searching for misplaced panel covers at the end of the job and scrambling to terminate panels at the end of the project. In addition, the early completion of the panel wiring prevents wire damage or theft.

The Panel Lockout can be used to keep breakers locked on. Critical equipment must not be accidentally shut down. So, the electrical panel can be locked and therefore unauthorized personnel are kept out.

The Panel Lockout is only 13 inches long, when retracted, and weighs only a few ounces. It fits in a toolbag and can be used on most electrical panels. With the two available extensions, the Panel Lockout can be used on panels from 14 inches to 37 inches wide. The cost of a Panel Lockout is only a fraction other lockout/tagout systems.

We also fabricate a Stainless Steel Panel Lockout. It can be used as a lockout tagout device. Additionally, the Steel Panel Lockout can help stop vandalism and theft in electrical panels and pull boxes. They are 16 inches long when retracted and fit panels or pull boxes from 17 inches to 27 inches wide.

The Steel Panel Lockout is designed to keep vandals from entering an electrical panel or a junction box. With the high price of copper, wire theft has been increasing on construction projects. Theft not only results in a loss of the value of the wire, but also the cost of re-installing it. By using our Steel Panel Lockout to lock panels and junction boxes before the power is turned on, thieves will have a difficult time trying to steal the wire.

The Steel Panel Lockout is also useful for temporary light and power panels on construction jobs. These are panels that should be accessed only by the electrician.

The Steel Panel Lockouts should not be used near exposed live bus or live wires.

Our “Clips for Panels without Screws” will work on most panels. You can see them in out web store. Clips for panels without screws

Click on the photos for close-ups.

The clips will not work on panel covers that wrap around the back box. For those types of panels you can install two screws as follows, or call us for another solution we may have for you

Drill two holes with a # 7 drill bit in the panel backbox edges (at arrows, see photo below). Tap the holes with a 1/4-20 tap. Then drill two corresponding 5/16 inch holes in the panel cover. Install two 1/4-20 panel screws (truss head) through the panel cover into the panel backbox. Then, the Panel Lockout can be used with the standard instructions. When the Panel Lockout is not in use, the two panel screws can remain installed and do not detract from the appearance of the panel.

An easy method to perform the above screw installation

1. Remove the panel cover and make sure there are no wires where you will be drilling. Replace the panel cover.

2. Drill through both the panel cover and the panel backbox at panel edge (at arrows, see photo) with a # 7 drill bit. Remove the panel cover.

3. Enlarge the two holes in the panel cover with a 5/16 drill bit. Tap the two holes in the panel backbox with a 1/4-20 tap.

4. Replace the panel cover and screw in the two panel screws.

CFR 29
[230.70(A)(1)]. In a multiple-occupancy building, each occupant must have access to the service disconnecting means [230.72(C)]. However, if electrical maintenance is provided by continuous building management, the service disconnecting means can be accessible only to building management personnel.

Comment——–The electrician (hired through the building management) is an agent of the building management and is authorized to control access. It is common for a tenant that needs access to a panel to call the building for access. In this case, the electrician’s contact information is on the tagout so access can be gained. The electrician would supervise any access so the circuit breakers he is working on do not get turned on.

The following is a letter ruling from OSHA regarding locking an electrical panel

October 24,

Mr. Jimmy Hill
Safety and Mission Assurance Directorate
Industrial Safety Department
Marshall Space Flight Center
Huntsville, AL

Dear Mr. Hill:

Thank you for your inquiry dated May 24, , regarding clarification of the definition for “Readily accessible” as contained in the Occupational Safety and Health Administration’s (OSHA) electrical standards. This letter constitutes OSHA’s interpretation only of the requirements discussed and may not be applicable to any question not delineated within your original correspondence. We apologize for the delay in our response. Your paraphrased scenario, question, and our response are provided below.

Scenario

It is not a standard practice at the Marshall Space Flight Center to lock electrical panels operating at 600 volts or less, but a request has been received from our Facilities Department to place locks that require a key to open all electrical panels. Locking the panels is to control access by unauthorized employees. A majority of these panels are lighting panels operating at 277 volts and are located throughout the center in office buildings, shop areas, and testing facilities. The breakers in these electrical panels are not used by employees as switches to turn equipment on and off daily.

Question: Does locking the electrical panels operating at 600 volts or less (to control access by unauthorized employees) violate OSHA electrical requirements for not being “Readily accessible” in the event of an emergency?

Response: In accordance with 29 CFR .399, Readily accessible is defined as “capable of being reached quickly for operation, renewal, or inspections, without requiring those to whom ready access is requisite to climb over or remove obstacles or to resort to portable ladders, chairs, etc.” This definition, however, does not preclude the use of a lock on the disconnecting means (circuit breakers panel), provided those, for whom ready access may be necessary, have a key (or lock combination) available. Additionally, the National Electrical Code (NEC) , Article 110.26, partly states, “Enclosures housing electrical apparatus that are controlled by a lock(s) shall be considered accessible to qualified persons.” Please note that the use of multiple locks, which requires different keys or combinations, on disconnecting switches may preclude the installation from being accessible or readily accessible to a particular individual who is authorized to access the panel.

Follow up

Thank you for your interest in occupational safety and health. We hope you find this information helpful. OSHA requirements are set by statute, standards, and regulations. Our interpretation letters explain these requirements and how they apply to particular circumstances, but they cannot create additional employer obligations. Note that our enforcement guidance may be affected by changes to OSHA rules. Also, from time to time we update our guidance in response to new information. To keep apprised of such developments, you can consult OSHA’s website at www.osha.gov. If you have any further questions, please feel free to contact the Office of General Industry Enforcement at 202-693-.

Sincerely,

Richard E. Fairfax, Director
Directorate of Enforcement Programs

Electrical workers who service circuit breakers face serious hazards, including electric shock, arc flash, and circuit overloads. These risks often stem from skipped safety procedures, particularly failure to follow proper lockout tagout procedures.

In alone, the National Fire Protection Association (NFPA) reported 126 fatalities and 2,380 non-fatal injuries due to electrical exposure. These figures underscore the importance of strictly following established safety practices. One of the most effective ways to prevent accidental re-energization during maintenance is by locking out the circuit breaker. This ensures it cannot be turned back on, either accidentally or intentionally, while servicing or maintenance work is in progress.

So, how do you properly lock out a circuit breaker and install a breaker lock device?

Key Takeaways

• Breaker lockout is essential to comply with OSHA's Lockout/Tagout (LOTO) regulations, preventing energy-related accidents during servicing or maintenance.

• Locking out a breaker ensures electrical equipment stays off during maintenance, avoiding sudden energization that can lead to injury or damage.

• Knowing various circuit breaker types helps in selecting the proper breaker lock device, ensuring secure and effective isolation of electrical energy sources.

• Verifying lockout success using voltage testers is a key step in LOTOTO, confirming no residual energy is present before maintenance begins.

What Is a Circuit Breaker and How Does It Work?

A circuit breaker is an electrical switch designed to automatically stop the flow of electricity when a fault, such as an overload or short circuit, occurs. Breakers are installed in electrical panels, where they connect the main bus bars to the individual circuit wires that distribute power throughout the electrical system. Each breaker monitors the electrical current flowing through its circuit. If the current exceeds safe levels, the breaker "trips" and opens the circuit to stop the flow of electricity.

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Traditional circuit breakers are mechanical switches that operate with a spring-loaded mechanism and a thermal or magnetic trip unit to detect faults and disconnect power. Modern circuit breakers, on the other hand, often include electronic trip units and more precise sensors. These allow for faster response times and better coordination with complex electrical systems.

Circuit Breakers vs. Fuses vs. Disconnects

Circuit breakers, fuses, and disconnects are all devices used to control and protect electrical circuits, but they work differently:

• • Circuit Breakers
    • Automatically trip to stop power during an overload or short circuit.
    • Can be reset after the fault is cleared.
    • Commonly used for ongoing circuit protection and easy restoration.
  • Fuses
    • Contain a metal wire that melts when overloaded, permanently breaking the circuit.
    • Must be replaced once blown.
    • Provide simple, one-time overcurrent protection.
  • Disconnects (Safety Switches)
    • Manually isolate equipment from the power source.
    • Do not trip automatically.
    • Used for maintenance or emergencies to provide a visible break in the circuit.

Types of Circuit Breakers

How to Lock Out a Breaker?

OSHA 29 CFR .147(a)(3)(i) standard requires “employers to establish a program and utilize procedures for affixing appropriate lockout devices or tagout devices to energy isolating devices, and to otherwise disable machines or equipment to prevent unexpected energization, start-up or release of stored energy in order to prevent injury to employees.”

A circuit breaker lock is a lockout tagout device that prevents unexpected electricity re-energization by keeping circuit breakers in the OFF position. During electrical equipment repair, the power source should be turned off and kept that way until the repair work is done.

Since breaker designs vary, choosing the correct breaker lockout device matters. Be sure to check out our Breaker Lock Solution Guidelines to find the right TRADESAFE Breaker Lockout Device for your specific breaker model and number of poles.

How to Install a Breaker Lock?

Now that you know the requirements for locking out a circuit breaker, the next step is learning how to install the breaker lockout device. In the sections below, we’ll walk through step-by-step instructions for installing the most commonly used breaker locks:

Clamp-On Breaker Lockout Devices

A clamp-on circuit breaker lockout is available in different sizes to accommodate medium to oversized circuit breakers without lockout holes in the toggle switch. Follow these steps for a proper clamp-on circuit breaker lockout installation:

1. Put the circuit breaker in the OFF position.

2. Place the clamp-on circuit breaker lockout device over the circuit breaker switch toggle.

3. Rotate the thumb wheel clockwise to secure the lockout device.

4. Close the lid and attach a lockout tagout padlock and tag to secure the lockout.

Universal Circuit Breaker Lockout Devices

A multi-pole universal circuit breaker lockout device is designed to lock out most single and multi-pole circuit breakers. This outlines the safe installation procedure for a universal multi-pole circuit breaker lockout:

1. Put the circuit breaker in the OFF position.

2. Attach the lockout device to the breaker switch (the universal breaker lockout device will easily lock out single and multiple-handle circuit breakers).

3. Place the device over the switch and lock the switch in the OFF position.

4. Slip the padlock shackle through one of the open holes in the top of the device, then attach the protective tag.

Miniature Circuit Breaker Pin Lockout Devices

A mini circuit breaker lockout is a device used for securing miniature circuit breakers in the OFF position. Installing Pin-In-Standard, Pin-Outward, and Pin-Out-Standard lockout devices follows the same basic process below. What changes is simply which device fits based on the type of breaker toggle you're locking out.

1. Put the mini circuit breaker in the OFF position.

2. Push the lockout device button to disengage the pins.

3. Position the pins into the small holes of the casing, then release the push button.

4. Attach a lockout tagout padlock through the lockout device hole to complete the lockout.

Tie Bar Lockout Devices

A tie bar lockout device is specifically affixed to multi-pole breakers that have tie bars connecting two or more toggles. To install it correctly, here’s what you need to do:

1. Place the mini circuit breaker in the OFF position.

2. Position the metal clip under the tie bar and between the poles.

3. Rotate the thumb wheel clockwise to secure the lockout device onto the circuit breaker.

4. Insert a TRADESAFE padlock through the hole to secure the device in the locked position.

Breaker Blocker Kit

A breaker blocker kit is a versatile lockout tagout system that uses adhesive-backed breaker blockers and interchangeable blocker arms. It is a good solution for switches that are oddly shaped or too large for standard breaker lockout devices. Here’s how to set it up the right way:

1. Shut off the circuit breaker.

2. Clean the area around the breaker thoroughly (breaker blockers usually need a clean surface to adhere properly).

3. Stick the base plate of the breaker blocker onto the panel or near the breaker using its adhesive backing.

4. Attach the blocker arm over the breaker toggle.

5. Some versions use a cover or locking plate that clicks into place over the blocker arm.

6. Insert a padlock through the designed holes to keep the blocker locked over the toggle, preventing reactivation.

Common Mistakes in Using Breaker LOTO Devices and How to Avoid Them

In the lockout tagout of circuit breakers, one common mistake is not fully engaging the breaker lock device’s mechanism. I once visited a manufacturing facility where the authorized employee applied a breaker thumb-screwed type lockout device, but didn’t tighten it securely. It slipped off when the panel was bumped, leaving the breaker off but unlocked.

This confused some workers who thought the circuit was back in service, while others believed it was still under maintenance. Luckily, no one was hurt, but it was a close call that led to a retraining session for the entire crew.

Another frequent error is using the wrong lockout device for the type of breaker. If the wrong type is used, the breaker handle might not be fully restrained, which gives a false sense of security and defeats the entire purpose of the lockout. Remember, the right lockout device depends on the type of breaker, the toggle style, and the environment you're working in.

How to Ensure a Successful Lockout

In addition to avoiding common mistakes when using breaker LOTO devices, authorized employees must perform a lockout tagout tryout (LOTOTO) to confirm the panel is in a zero energy state. This step is essential to confirm that the breaker lockout tagout is fully effective and the equipment is safe to work on.

I've seen workers skip voltage verification after applying the lockout device. Some assume that once the breaker is turned off and locked, the circuit is safe, especially if the panel is labeled. In reality, labeling can be inaccurate, or the wrong breaker may have been locked out, leaving the circuit still energized. In other cases, teams rush to complete the task and see voltage testing as an extra step rather than a requirement.

Expert Insights

“In my experience, the only safe way to test that electrical equipment is safe to work on is using a voltage indicator, in conjunction with a proving unit, before and after testing for dead, to prove the voltage indicator is working correctly. Non-contact devices, such as volt sticks or pens, cannot be relied upon for this purpose. If you’re going to put tools or your hands on any electrical equipment, you need to be absolutely certain it’s safe to work on before you touch it…” — Mark Platten, a Commissioning, Compliance & COHE Manager with over 35 years’ experience, shared his thoughts on “What are the Most Effective Ways to Verify Electrical Lockout and Tagout Procedures?”

Breaker LOTO Installation FAQs

How do you disable a breaker?

To disable a breaker, switch it to the OFF position and apply a properly rated breaker lockout device to prevent it from being turned back on. Follow your facility’s lock out tag out circuit breaker procedure, including tagging the breaker and verifying zero voltage before starting any work.

How to unlock a breaker lock?

Only the person who applied the lock should remove it. To unlock, remove the padlock and tag, then take off the breaker lockout device. This should only be done after the work is complete, and it’s been confirmed that it’s safe to re-energize the equipment.

Can one lockout device fit all breakers?

No. Lockout devices must match the specific type and size of the breaker. For example, miniature circuit breakers often require pin-in or pin-out devices, while multi pole breakers with a tie bar need a tie bar lockout. Using the wrong device may fail to secure the breaker properly, compromising safety.

Is it OSHA compliant to use non-branded lockout devices?

OSHA does not require lockout devices to be from a specific brand. However, the devices must be durable, standardized, and capable of effectively preventing energy release. Non-branded devices are acceptable as long as they meet these criteria and are used correctly.

What happens if I skip installing a lockout device during repairs?

Skipping the installation of a breaker lockout device is a serious safety violation. It leaves the breaker vulnerable to accidental re-energization, which can cause electrical shock, arc flash, or even fatal injuries. It also puts your facility at risk of non-compliance with OSHA’s lockout tagout standards.

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