Electrical hazards are among the most serious risks lift engineers face day-to-day. Unlike some hazards that are visible and easy to assess, electricity is silent and unforgiving. Whether you’re fault-finding, carrying out repairs, or working on a live panel, the risk of electrocution, equipment damage or fire is always present.
This guide looks at common electrical tools used by engineers, the associated hazards, and more importantly, how to stay safe.
Electrical tools used by lift engineers
The most common tools used by lift engineers include shorting wire kits and electrical test meters and probes. These are often used for fault finding, such as when a lift is not working or becomes stuck. The kits create a temporary, controlled “short” in the circuit to isolate which component is preventing a lift from operating. Additionally, shorting kits are used during maintenance and repairs to bypass safety circuits while work is being carried out.
An essential and long-used tool by engineers is a test meter or multimeter to measure volts, amps and ohms. These are commonly used in lift maintenance for checking Variable Frequency Drives (VFDs) for proper voltage and current delivery, checking control systems, as well as safety component testing.
Risks of using electrical tools
When working on or near live equipment for fault finding or repairs, there is a heightened risk of electric shocks and burns.
Multimeter risks:
- Arc flash and explosion: Using a multimeter without the correct Measurement Category (CAT) rating (for example, using a CAT II meter on a CAT IV utility feed) can result in catastrophic failure when exposed to high-energy transients often found in lift motor rooms.
- Dead short creation: A common mistake is attempting to measure voltage with the probes inserted into the current (A) ports, or with the dial set to resistance (Ohms). This can create a direct short circuit, potentially leading to an arc blast.
- Electric shock: Damaged probe insulation or failure to wear appropriate insulated gloves can result in “hand-to-hand” shock. This is particularly dangerous, as the current can pass directly through the heart.
- False ‘dead’ readings: A blown internal fuse or faulty meter may display 0V on a live circuit. Engineers should always follow the Live–Dead–Live testing method to confirm the meter is functioning correctly before assuming a circuit is safe.
Shorting wire kit risks:
- Unintended car movement: Bypassing safety interlocks (such as door switches) can cause the lift to move unexpectedly. If a shorting lead is incorrectly applied to landing or car door circuits, the lift could start while a passenger is entering or exiting, leading to severe entrapment injuries.
- Forgotten bypasses: One of the most critical hazards is failing to remove a temporary link after testing. This can leave a safety circuit permanently bypassed, making the lift seriously dangerous for the next user.
- Simultaneous bypassing: Bridging both car and landing door circuits at the same time is extremely dangerous and should be avoided. Where absolutely necessary, it should only be carried out with a second competent person present to maintain clear communication and control.
- Fire hazards: Using unauthorised or makeshift shorting leads in place of proper circuit protection (such as fuses) can prevent systems from tripping during an overcurrent event. This can result in overheating, melted wiring, and potential fire.
How to prevent electrical hazards
Exposure to high-voltage circuits or faulty systems can lead to serious injury or fatality if not properly controlled. For that reason, extreme caution must always be taken when working with electrical equipment.
Here are some of the core methods to help reduce electrical risks:
- Only authorised and competent persons should use electrical tools
- Engineers should be able to read and interpret electrical drawings
- The correct PPE must always be worn
- Tools should be inspected for damage before use
- Always refer to the manufacturer’s instructions—particularly for multimeters, as different models have different functions and limitations
- Only install a shorting lead when power has been properly isolated
- A record of any temporary links installed should be maintained
- Multimeters should be proven on a known live source before use (Live-Dead–Live method)
Lift systems rely heavily on electrical components, so when things go wrong, the consequences can be severe.
Engineers must remain vigilant, using the correct tools, following safe systems of work, and never taking shortcuts when it comes to electrical safety.
To help reinforce this knowledge, we offer Toolbox Talks designed specifically for lift engineers:
- Electrical Shorting Kits – Service & Repairs
- Electrical Shorting Kits – Construction & Large Repairs
- The Basics of an Electrical Test Meter
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