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Safety (batteries, motors, …)*

Summary: PPE, anti short-circuit, lockout, best practices.

1) General principles and PPE

  • Very low voltage ≤ 60 V but high energy: risks of arc and burns. Use insulating gloves, visor, fitted clothing; ban jewellery/metal objects.
  • Clear and ventilated work area; suitable extinguisher nearby (class ABC/CO₂, according to local instructions).
  • Systematic lockout: disconnect power, lock/tag before intervention.

2) Lithium batteries 48–51.2 V — safe installation

  • Mechanical integration: avoid shocks/crushing; rigid support; dampen vibrations; suitable IP rating (dust/mud/water).
  • Wiring: minimal lengths; suitable sections; grommets/sleeve; torque settings respected; polarities identified.
  • Protections: DC fuse near +; accessible disconnect; avoid loose tools/metal objects.
  • Charging: charger compatible with chemistry/voltage; prohibited < 0 °C without dedicated system; monitor during initial charges.
  • Storage: 40–60% SoC, 10–25 °C, dry area; quarterly voltage check.
  • BMS: check thresholds (under/overvoltage, overcurrent, temperature) and event log; cell balancing.

3) Batteries — incidents and responses

  • Short-circuit/arc: cut immediately; check for damage; replace marked cables/connections.
  • Abnormal heating: stop use; ventilate; find cause (excess current, insufficient dissipation, poor contact).
  • Odour/smoke/electrolyte leak: isolate area; PPE; absorb with suitable product; do not spray; contact specialised channel.
  • Fire: follow local instructions; water possible for cooling/firefighting depending on packs; CO₂/ABC on peripherals; do not reuse an involved pack.

4) Motors, reducers, transmissions — mechanical risks

  • Entanglement: Ban loose clothing, hair, unsuitable gloves
  • Prevent: guards, prohibited areas, signage; check clearance before start-up; accessible emergency stop button (E-Stop).
  • Fixings/chassis: correctly sized; torque checks after commissioning and periodically.
  • Burns: hot surfaces (motor/controller); provide screens/guards and warnings.

5) Electrical — power and logic wiring

  • Power/logic separation; robust ground returns; avoid ground loops.
  • Connectors and IP: selection suitable for current/IP; anti-loosening locks; seals in good condition.
  • Twisted/shielded cables for signals (Hall/encoder/CAN); 120 Ω terminations at CAN bus ends.

6) Safe commissioning

  1. Complete visual inspection (mechanical/electrical/IP). Check torque settings, polarities, fuses.
  2. First power-up via limited supply/variable speed drive or provisional fuse; BMS/controller telemetry monitored.
  3. No-load tests then light load (gentle ramp); monitor currents/voltages/temperatures; check emergency stop.
  4. Documentation: record parameters (BMS/controller), torques, dates; label.

7) Regulatory reminders and best practices

  • Respect manufacturer instructions (batteries, controllers, motors).
  • Use of insulated tools in good condition; prohibition of high-pressure washing on non-IP connectors.
  • Waste management: batteries and electrical components via approved channels; traceability maintained.

Quick checklist

  • Lockout and PPE in place
  • DC protections (fuse/disconnect) and polarities identified
  • Separate power/logic wiring; shielding/CAN terminations
  • Guard protections for rotating parts; E-Stop accessible
  • Incident procedure (fire/leak) known and extinguisher present


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*: The technical information presented in this article is provided for guidance only. It does not replace the official manuals of the manufacturers. Before any installation, handling or use, please consult the product documentation and follow the safety instructions. Torque.works cannot be held responsible for inappropriate use or incorrect interpretation of the information provided.