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Solving a Wiring Mess?

FueledByRamen asks: "While trying to run a new power line for a large Sun mass-storage cabinet (located nowhere near a 220 outlet of course), I had the misfortune of needing to pop the lid on my main power distribution panel (previously opened in the late 80s). The whole thing is a rats nest and probably a fire hazard - old-style wiring with broken-down cloth/plastic insulation strewn everywhere, and the utility's incoming power cables have some sort of junction in them that's the size of a 1-liter bottle (on each wire) and is covered in layers of electrical tape. Even (gently) putting the panel back on jiggled something important, and there was a nasty cracking noise and half the breakers blew (all breakers in one of the 2 columns). I've worked with mains voltage in the past (wiring new rooms, installing lighting), but nothing on this scale, both in terms of complexity and potential for death. How do you industrious Slashdot readers go about fixing a mess like this (on a tight budget, no less) without getting a mains-induced glimpse at the great beyond?"

37 of 769 comments (clear)

  1. Good grief by mao+che+minh · · Score: 5, Insightful

    Good god man, leave that mess alone and hire a professional that knows what they are doing. Don't ever put your life in the hands of Slashdot; are you utterly insane?

    1. Re:Good grief by Frymaster · · Score: 5, Funny
      what you really need is a wireless power distribution set up. there's one here:

      http://www.geocities.com/Area51/Shadowlands/9654/t esla/projecttesla.html

    2. Re:Good grief by Kircle · · Score: 5, Funny

      I think what he really means is if anyone from /. is willing to do this for him. In other words, he's saying: "if someone dies, please let it be you and not me."

      --

      -- Kircle

    3. Re:Good grief by Catbus · · Score: 5, Insightful

      I think you get a qualified electrician to look at this and fix it. If the budget does not permit this, change the budget or consider the business failed. Next go-around, get better due-diligence review of the facilities. We techies can do some power if we are know what we are doing, but this sounds like it is out of our league. One may well have to turn off service power at the pole (or other building entrance) to redo this. Also, you are talking big conductors here, which our techie-tools can't handle. Leaving it alone is bad because there is already evidence of loose connections and grounding problems that will cause your 220 volts to vary over a wide range intermittently, eventually damaging the equipment, and possibly causing electric shock to employees touching poorly-grounded cabinets.

    4. Re:Good grief by dhogaza · · Score: 5, Informative

      It's the friggin' *law* in most jurisdictions to get a licensed electrician to do this work, and for very good reason.

      In a facility I ran years ago I smelled smoke in our main distribution panel. Called our electrician and he *immediately* turned white, got out of there dragging me with him, closing the door to the small power distribution room behind him and immediately went to the building's main distribution breakers next to the elevator shaft on the bottom floor and turned off all power to our floor.

      Why? He'd seen the insulation bubbling on the aluminum power cable that was connected to the main copper bus for the breaker box.

      It had been connected without anti-oxidation gel and the aluminum had oxidized increasing resistance to the point where the insulation was near burning.

      He told me that an electrician had been killed earlier in the year when a suburban shopping mall's main panel blew up as he was inspecting it, after having been called in during the wee hours of the night by the fire department after a report of smoke had been called in.

      If the original poster's company doesn't own the building then the landlord can be forced to pay, just call in the friggin' city electrical inspector and after he shits his pants your building owner will be paying to rewire the box ASAP.

    5. Re:Good grief by mizhi · · Score: 5, Funny

      Well shit, now we know how the blackouts occurred.

      --
      Humorless sig goes here.
    6. Re:Good grief by cybermace5 · · Score: 5, Informative

      It's a great idea to call in an inspector periodically. Even the best-wired distribution box will eventually go bad and possibly cause a fire.

      Why? Stuff expands when it is heated. Your connections are continually undergoing varying stresses depending on the current. When a connection works itself slightly loose, the resistance increases and the process speeds up.

      Where I work, we have the local power service come in and take pictures of our distribution boxes with an infrared camera. That's a great way of pinpointing connections that are heating up too much.

      This is the reason a computer can stop working, too...sometimes you can just pop the lid, wiggle everything and cinch it down, and it works.

      --
      ...
  2. Auditioning for the Darwin award??? by TopShelf · · Score: 5, Insightful

    Maybe it's just me, but some things are worth paying for. I prefer juice in my stomach, not coursing through my entire body...

    --
    Stop by my site where I write about ERP systems & more
    1. Re:Auditioning for the Darwin award??? by Cyclometh · · Score: 5, Interesting

      I did some theater work, in the totally amateur area, and on one production that I produced, I had to wire the lighting panel into the mains, because the theater was built in 1924 and still had most of its original lighting equipment. We figured that 75-year old rheostat dimmers the size of car tires that made a sound like a chainsaw when you pulled the foot-long lever weren't going to work well for our production.

      So we borrowed/rented the equipment we needed, and the lights, wired everything up, and got ready to hook the main control box up. I got the pigtails ready and opened up the panel where the theater tech told me the power should be.

      Inside, three very large, uninsulated, copper bars going from top to bottom.

      All the others with me just looked at it and said "all yours, man". Great. So I double-checked the power was turned off to this panel- it had a very large switch, and you could *see* the switches disengage, but I still didn't trust that, then triple-checked it with a meter.

      I was still nervous as all hell just putting my hand near these things, even knowing they were off. One handed, keeping the other hand behind me (I remembered that advice from my HS electronics teacher) I undid the big allen bolts and hooked the pigtail up.

      It actually worked first try. Undoing it at the end of the production was almost as harrowing as the first time. I had the old mantra of labratory physics running through my head- "Hot glass looks exactly like cold glass", only I had modified it to "live copper looks exactly like dead copper". I also knew that if it was live, I probably wouldn't even know it before I was killed or rendered unconscious.

      Yeesh. I still can't believe I was stupid or bold enough to do that.

      In keeping with the other folks here, I'd say to the original asker, hire a bloody electrician, and don't get near the thing until someone tells you it's safe. Budget be damned, you don't want to risk your life on something like that.

      Hooking up a simple pigtail is one thing, futzing around in the panel you described is suicide.

      On a side note, I once got nailed by a 220 V dryer when I was about 8 years old. I was reaching for a sock that had fallen behind it, and touched one of the leads that was left exposed (!). It threw me about 15 feet across the laundry room and put a crack in the door where I hit it.

  3. Obvious answer? by Icepick_ · · Score: 5, Redundant

    Hire an electrician.

  4. Good, cheap, fast: pick any two by sphealey · · Score: 5, Insightful
    ow do you industrious Slashdot readers go about fixing a mess like this (on a tight budget, no less) without getting a mains-induced glimpse at the great beyond?"
    There is a reason why good industrial electricans charge a lot for their services: they work with dangerous stuff, and they know what they are doing. Get an estimate from a good one. If the powers-that-be refuse to approve the project, resign. That day.

    sPh

  5. Don't you have any interns at your place? by Anonymous Coward · · Score: 5, Funny

    That's the kind of job they get to do.

  6. Blackout by EmagGeek · · Score: 5, Funny

    Are you sure YOU weren't the cause of the blackout of 2003?

  7. Hmm, well now ... by petabyte · · Score: 5, Insightful

    I might not speak for everybody but I'd imagine that the majority of people went "Hire an electrician" when they read that story. I really don't think you want to be mucking around in there with "some sort of junction in them that's the size of a 1-liter bottle" as you don't appear to know what that is (neither do I).

    I know you want to save money but you're likely to fry the electric equipment in your establishment and might take yourself with it. Hiring a professional would likely be cheaper in the long run.

  8. Re:buy the cheapest parachute you can! by WTFmonkey · · Score: 5, Funny

    Heh, reminds me of a story. I used to work at Home Depot, and one of the regular electrical customers said that, in whack-job wirings like you have, he would be able to tell the difference between 110v and 220v by grabbing it the wire. If it hurt more, it was 220. If it hurt less, it was 110. He quit coming in one year, and I always wondered what happened to him...

  9. I don't have my power back yet by ipnetworker · · Score: 5, Funny

    You Insensitive Clod.

    --
    Port 80, we dont need no stinckin port 80.
  10. Phrases most commonly heard before death by siskbc · · Score: 5, Funny


    5) Mike Tyson sounds like a girl.

    4) Honey, that's just the PMS talking.

    3) [Redneck accent]Hey y'all, watch this...

    2) Betcha can't...

    1) We'll save a lot of money by not hiring an electrician...

    'Nuff said.

    --

    -Looking for a job as a materials chemist or multivariat

  11. Re:Good, cheap, fast: pick any two-Insurance. by Anonymous Coward · · Score: 5, Informative

    There's also insurance reasons as well. Having someone other than a qualified electrician do the work can void your fire insurance.

  12. wording by holy_smoke · · Score: 5, Interesting

    send an email to your PHB that says things like "fire hazard" "risk to operations" "danger to employees and $$$$ equiment" "violation of code" and/or "insurance risk". That should get you the authorization you need to do whatever needs to be done - which, as others have pointed out, is HIRE A PROFESSIONAL.

    --
    Is the juice worth the sqeeze?
  13. If you have to ask... by IIRCAFAIKIANAL · · Score: 5, Insightful

    ... then you shouldn't be doing it.

    Sorry, but this is the kind of thing that only years of experience can help with. If you didn't look at it and already know how to approach the problem, you probably shouldn't be messing around in there, unless you have all the time in the world to experiment and learn your way through the mess.

    First I was surprised that IANAL advice hasn't landed some "Ask Slashdotter" in prison. Now we're aiming for our first fatality?

    --
    Robots are everywhere, and they eat old people's medicine for fuel.
  14. Re:Good grief - In the good old days by Anonymous Coward · · Score: 5, Funny

    What, you're scared of 220 Volts ? When we were growing up, we walked 200 miles through six feet of snow, wearing no shoes, and we repaired 2000 volt circuits with our bare hands. :-)

  15. Future Ask Slashdot Questions by Hoi+Polloi · · Score: 5, Funny

    How do I perform brain surgery on myself?

    What is the best way to travel about in a war zone?

    What is the best way to tell my spouse that she needs to lose A LOT of weight?

    How can I get close to the President while carrying a handgun?

    How can I steal power from a high tension line?

    --
    It is by the juice of the coffee bean that thoughts acquire speed, the teeth acquire stains. The stains become a warning
    1. Re:Future Ask Slashdot Questions by aminorex · · Score: 5, Funny

      1) Cocaine for local, and lots of valium. Get
      some mirrors, peel back the skin, and use a
      hole saw or dremel depending on what kind of
      access panel you want. Apply more cocaine.
      Apply more valium. Get a paper clip hot with
      a bunsen burner and cauterize the tumor.

      2) Get the best night vision goggles you can,
      and ceramic body armor, kevlar helmet. Don't
      carry anything that looks remotely like a weapon.
      Depending on prevailing rules of engagement, wear
      a red cross. Use inconspicuous local vehicles,
      the lower-tech the better. Cease moving when
      you get a hint of a battle group nearby.
      Try to stay close to heavy cover, such as
      large rocks, substantial depressions in the earth.

      3) Get a skinny mistress.

      4) Join the secret service.

      5) Invest in Enron.

      --
      -I like my women like I like my tea: green-
  16. Re:Good, cheap, fast: pick any two by rmohr02 · · Score: 5, Informative

    Don't resign. A worker can notify his supervisor that due to what the worker believes that doing the task placed before them will put them in imminent danger, he can refuse to do that task. The worker then needs to fill out a form or two and contact the Occupational Safety & Health Administration. The worker cannot be disciplined for refusing to work in a dangerous situation.

  17. Re:buy the cheapest parachute you can! by psykocrime · · Score: 5, Informative

    I've felt both a time or two (accidentally). 110 is really more of a tickle and certainly won't kill you.

    You've got to be respectful of it but with 110 I didn't even realize I was being shocked until well after the fact.


    Dude, 110 volts is most certainly enough to kill. True, most of us have been "tingled" by 110/115 a few times, and didn't die... all that proves is that we were lucky on those occassions.

    For an interesting discussion of why low voltages *can* be deadly, see this page.

    The bottom line is, lower voltages tend to be "safer" due to the resistance of your body, and the fact that low voltage power sources also usually have a fairly low current capacity. But try wetting your hands and grabbing the leads from an arc welder set on 200+ amps sometime, if you don't think low voltage can f#@k you up.

    --
    // TODO: Insert Cool Sig
  18. Photograph! by stuckatwork · · Score: 5, Interesting

    How 'bout putting up a picture of that mess for us to enjoy?

  19. In the same vein... by Soko · · Score: 5, Funny
    (Shamelessly lifted from this page, though I've seen many versions posted in college and in electrical shops...)
    1. Beware the lightning that lurketh in an undischarged capacitor, lest it cause thee to be bounced upon thy buttocks in a most ungentlemanly manner.

    2. Cause thou the switch that supplies large quantities of juice to be opened and thusly tagged, so thy days may be only on this earthly vale of tears.

    3. Prove to thyself that all circuits that radiateth and upon which thou worketh are grounded, less they lift thee to high frequency potential and cause thee to radiateth also.

    4. Take care thou useth the proper method when thou taketh the measure ofhigh voltage circuits so that thou doth not incinerate both thee and the meter; for verily, thou hast no account number and can easily be replaced, the meterdoth have one, and as a consequence, bringeth much woe unto the supply department.

    5. Tarry not amongst those who engage in intentional shocks, for they are not long for this world.

    6. Take care thou tampereth not with interlocks and safety devices, for this will incur the wrath of thy seniors and bringeth the fury of the safety officer down about thy head and shoulders.

    7. Work thou not on energized equipment, for if you doth, thy buddies will surely be buying beers for thy widow and consoling her in other ways not generally accepted by thee.

    8. Verily, verily I say unto thee, never service high voltage equipment alone, for electric cooking is a slothful process and thy might sizzle in thine own fat for hours on end before thy Maker sees fit to end thy misery and drag thee into His fold.

    9. Trifle thou not with radioactive tubes and substances, lest thou commence to glow in the dark like a lightning bug, and thy wife be frustrated nightly and have no further use for thee except thy wage.

    10.Commit thou to memory the works of the prophets, which are written in the instruction books, which giveth the straight dope and which consoleththee, and thou cannot make mistakes, sometimes, maybe.

    Author unknown
    Soko
    --
    "Depression is merely anger without enthusiasm." - Anonymous
  20. Hang a LOCK. by karlandtanya · · Score: 5, Informative
    Maybe they do where you live, but here, you hang a lock. The sign you describe is attached to the lock and has your picture on it, contact information, and contact information for your supervisor and employer.

    Don't have one of those? THAT'S BECAUSE YOU'RE NOT FARKIN' QUALIFIED TO DO THE WORK!

    If you have not had the correct training, you CAN NOT safely lock out equipment. Sure. You locked it out. You stuck your wiggy in the wall socket to make sure you got a buzz. You tested each terminal and they were all dead. You started stripping wires. You reached way into the cabinet to unscrew some terminals in the back. It got dark and the building's outside lighting circuit turned on. Guess what? Someone ran the lighting circuit through the box.

    oopsie.

    You don't know what you're doing. Neither does the person who "told you how" to do this safely. Hire a professional.

    --
    "Reality is that which, when you stop believing in it, it doesn't go away." - Philip K. Dick
  21. Re:Good grief - In the good old days by berzerke · · Score: 5, Funny

    What, you're scared of 220 Volts ? When we were growing up, we walked 200 miles through six feet of snow, wearing no shoes, and we repaired 2000 volt circuits with our bare hands. :-)

    You call that tough. When I was a kid, we didn't even have hands.

  22. Safety practices around high power. by mikech@rbsgi · · Score: 5, Interesting

    I used to write software at a high-energy physics lab. The technicians would put padlocks that only they had keys for on switches when they powered something down. Removing someone else's lock was grounds for immediate dismissal. If someone accidentally left a lock on something, they had to personally remove it or (you guessed it) face dismissal. They took these rules very seriously.

    1. Re:Safety practices around high power. by RollingThunder · · Score: 5, Interesting

      In fact, at the Esso terminal my dad worked at, the lockout "scissors" were set up with eight sets of holes in them. You threw the breaker to off, opened the scissors, then closed them so the "teeth" went through the hole to lock it out.

      Then, you put your lock on, through one hole. Your buddy put HIS lock on through another hole. Anyone else that came along later? They put their lock on too, through another hole.

      That way, the first guy doesn't mistakenly power the system back on, zotting some other guy that came along after him and went "Oh, OK, it's already locked out."

  23. Re:Good grief - In the good old days by NickDngr · · Score: 5, Interesting

    it's not the volts it's the amps that getcha

    God, I knew someone was going to say that. Ohm's law... I=V/R. If the voltage goes up, so does the current. They are not mutually exclusive.

    --
    Yoda of Borg am I! Assimilated shall you be! Futile resistance is, hmm?
  24. Electrician's Comment on 240V by billstewart · · Score: 5, Insightful
    An American friend of mine was over in Australia, and watched an electrician who was being really conservative with turning all the power off while installing things. Since that didn't seem to be the usual Aussie approach to life, and since electricians in the US usually aren't that careful, he asked him about it. The guy replied that the difference between wimpy US 110 and 240 was "When you touch 240, you bounce about 3 meters farther.".

    Basically, don't fsck with the stuff unless you know what you're doing.

    --

    Bill Stewart
    New Fast-Compression-only CPR http://preview.tinyurl.com/dy575ks
  25. Whats next - Solving a sanitary mess? by plierhead · · Score: 5, Funny
    FueledByRamen, you're one crazy son of a bitch, but I salute you - you've got balls (well, at the moment you have, assuming you haven't tried out any of the /. advice yet). And I am really looking forward to your next post "Solving a sanitary mess" when your toilets block up.

    Seriously though, there is life outside whatever burnt out dot com shell you are currently living in, with only the roaches keeping you company. You need to get out and get your bare feet on the grass for a while. Smoke something. Lie in the sun with your eyes closed. Try and forget there was ever a place and time when you thought it would be smart to do your own high voltage wiring.

    --

    [x] auto-moderate all posts by this user as insightful

  26. Why Doctors are not Electricians by sterno · · Score: 5, Insightful

    I lived in a rented house in college that had what turned out to be dangerous wiring.

    LESSON 1: Polarity

    Here's a cool tip for you. When wiring up electrical outlets, if you reverse the hot and the neutral lines, you actually create a voltage potential between the outlets. I discovered this because I touched the stove and the refridgerator at the same time accidentally. I got a huge jolt, shook a bit, and called the land lord.

    LESSON 2: Breakers and Wiring Guages

    If you should ever run wiring in your house, you need to make sure that the breaker that you use matches the capabilities of the wiring. If you should decide to run wiring into an attic using 15 amp capable wiring, it is a bad idea to put a 30 amp breaker on it. It's an even worse idea to hook up approximately 27 amps worth of electrical heaters to this circuit because it will cause the wiring in the wall to catch fire. Of course if one assumes that the person wiring the house isn't insane, you may not know to avoid plugging in said heaters.

    LESSON 3: DOCTORS ARE NOT ELECTRICIANS

    Eletricity isn't brain surgery, and just as you don't want an electrician siticking sharp metal objects into your brain, you don't want a doctor futzing with wiring. Actually I suppose if you are a doctor who does know how to work with electricity it would be okay, but the one who had previously owned our house had no clue on the subject. Worse, he had no clue and he mistakenly thought that he knew everything.

    So, if you look in the electrical box and it instills fear in you, call a professional. Don't even think of doing it yourself.

    --
    This sig has been temporarily disconnected or is no longer in service
  27. Reminds me of the time ... by ShipIt · · Score: 5, Funny

    I worked at a medium sized amusement park while in college. The park was over 35 years old and much of the wiring and junction boxes were equally as old.

    Late one summer night, with the park full of people, all the lights on 'main street' went off.

    I was nearby the park's main junction box and helped one of the engineers, an unassuming guy who had worked at the park for years, by holding a flashlight while he started work on the box.

    The box was ancient. Cloth wrapped wires. Giant fuses. Old rusty exposed mechanical switches. The works. For whatever reason, one of the main switches had popped open. The engineer first tries popping it back in place. The lights flicker and it just pops back out.

    The guy looks at me and says "Point the light at the ground. Help me find some old wire". He searches around with his hands for a minute and finds a snipping of some very heavy guage plastic insulated wire.

    To my shock, the guy closes the switch shut with one hand while using the other to hold the insulated part of the wire and *arc-welds the switch shut* with the wire's exposed conductor! Sparks flew, the lights snapped back on, and I damn near shit my pants. This good old boy engineer didn't even blink. "That should hold it until we can get someone out tomorrow".

    The only thing I can figure is that he was somehow electrically insulated, perhaps from his huge set of balls for even considering something like this.

  28. Re:Good grief - In the good old days by Jardine · · Score: 5, Funny

    The key too handling high voltages safely, is to become a good resistor

    So resistence...is not futile?