Safety Guidelines

Essential safety protocols for high-voltage pulse charging experiments

High Voltage Safety

Hazards

⚡Flyback Pulses: Hundreds of volts to several kV can cause severe electric shock, cardiac arrest, burns

⚡"One hand rule" is a MYTH: Touching one terminal can be lethal if you're grounded through feet

⚡Arc flash: Can cause severe burns and eye damage

⚡Involuntary muscle contraction: Can cause falls and impact injuries

Protection Measures

Insulation

  • All high-voltage components fully insulated
  • Terminals covered with heat-shrink tubing or electrical tape
  • Use high-voltage rated wire insulation (600V minimum)
  • Coils insulated from grounded objects

Enclosure

  • Mount circuitry in non-conductive enclosure
  • If metal enclosure, properly ground it and ensure internal insulation
  • Interlock switches: Power cuts off when enclosure opened

Working Procedures

  • ALWAYS disconnect power before touching circuits
  • Discharge capacitors before handling (use insulated discharge tool)
  • Work one-handed when possible (keep other hand behind back) to reduce heart current path
  • Rubber-soled shoes for insulation from ground
  • Never work alone when testing high-voltage systems

Personal Protective Equipment (PPE)

  • Safety glasses (arc flash protection)
  • Insulated gloves rated for voltage (leather over rubber for HV work)
  • Non-conductive work surface (rubber mat)

Clearances

  • Rule of thumb: 1mm per kV minimum
  • 500V → 0.5mm (inadequate, use ≥3mm)
  • 3kV → 3mm (minimum, use ≥10mm)

Battery Safety

Overcharging Hazards

Danger: Overheating, thermal runaway, fire, explosion

Prevention:

  • Monitor battery temperature continuously
  • Use appropriate charge termination methods
  • Implement thermal cutoffs
  • Never leave charging unattended initially

Thermal Runaway (Lithium Batteries)

Lithium batteries can enter thermal runaway - a chain reaction leading to fire or explosion

LFP (Lithium Iron Phosphate): Safer than other Li-Ion chemistries but still poses risk

Continuous monitoring essential during IPC

Terminate charging immediately if temperature rises excessively

Hydrogen Generation (Lead-Acid)

Lead-acid batteries generate explosive hydrogen gas during charging

  • Ensure adequate ventilation
  • No sparks or open flames near batteries
  • Use sealed AGM batteries when possible
  • Monitor for bulging or leaking

Chemical Hazards

Lead-Acid: Contains corrosive sulfuric acid

  • Wear gloves and eye protection
  • Have neutralizing agent (baking soda) available
  • Avoid shorting terminals

RF Radiation Safety

Microwave Exposure Hazards

For systems using 2.4 GHz magnetrons:

  • Eye cataracts from microwave exposure
  • Internal organ damage from tissue heating
  • RF burns from high field strength

Protection Measures

  • ✓Proper shielding (Faraday cage) for microwave systems
  • ✓Verify no microwave leakage with appropriate detector
  • ✓Maintain safe distance from RF sources
  • ✓Use non-metallic tools when near strong RF fields

FCC Compliance

Unlicensed transmission can violate FCC regulations

Recommendations:

  • Use shielded enclosures
  • Stay within ISM bands (2.4 GHz) if using RF
  • Use FCC type-accepted equipment (e.g., CB radio at 27 MHz)
  • Avoid disturbing ham bands, aviation, telecom frequencies

Fire Safety

Fire Hazards

  • Component failure can cause fires (resistors, transistors, wiring)
  • Battery thermal runaway can ignite surroundings
  • Sparks from high voltage can ignite hydrogen gas
  • Overheated wiring from excessive current

Fire Prevention

  • ✓Have ABC fire extinguisher readily accessible
  • ✓Use proper wire gauge for current levels
  • ✓Fuses or circuit breakers on all power lines
  • ✓Non-flammable work surface
  • ✓Smoke detector in work area
  • ✓Never leave experiments running unattended

Emergency Procedures

Electric Shock

  1. DO NOT touch the victim if still in contact with electrical source
  2. Cut power immediately using insulated method
  3. Call 911 / emergency services
  4. If trained: CPR if victim not breathing
  5. Treat for shock: lay flat, elevate legs, keep warm

Fire

  1. Cut power if safe to do so
  2. Use ABC fire extinguisher
  3. DO NOT use water on electrical fires
  4. Evacuate if fire spreads
  5. Call 911 / emergency services

Chemical Exposure

  1. Remove contaminated clothing
  2. Flush affected area with water for 15+ minutes
  3. For acid: neutralize with baking soda solution
  4. Seek medical attention
  5. Have MSDS (Material Safety Data Sheets) available