This is a situation where you need to prioritize safety and code compliance. Here's a breakdown of why and how you should address it

Why this is a problem:
Safety Hazard

The setup you described is a significant safety hazard. Here's why:

Overloading

Plugging multiple lights into a single power strip and then into a 4x4 box can easily overload the circuit, leading to overheating, breaker tripping, and potentially a fire.

Improper Wiring

Using SO cord in a fixed installation is generally not permitted by electrical codes. SO cord is designed for temporary connections and not for permanent wiring.

4x4 Box Misuse

A 4x4 box is designed for splicing and housing wiring connections, not as a junction for multiple cord-and-plug connected devices. It's not rated for the potential heat and stress of that many cords.

Lack of Overcurrent Protection

The lights individually might have low wattage, but collectively, they could exceed the ampacity of the power strip or the branch circuit supplying the power strip. The power strip itself may not provide adequate overcurrent protection for this type of application.

Non-compliant with Code

This installation almost certainly violates National Electrical Code (NEC) or local electrical codes, which are designed to ensure safety and prevent electrical hazards.

How to address the situation


Talk to the Maintenance Guy First



Approach

Start by talking to the maintenance guy directly in a calm, non-accusatory manner. Frame it as a safety concern, not as "catching him doing something wrong."

Explain the Risks

Explain why the setup is unsafe. "Hey, I noticed the lighting setup you're working on for the lathe. I'm a bit concerned about the way it's wired. Plugging all those lights into a single power strip and then into a 4x4 box could overload the circuit and potentially cause a fire."

Offer Solutions

Suggest alternative, safer ways to provide lighting for the lathe. Examples: Using properly wired, code-compliant lighting fixtures mounted to the lathe. Installing a dedicated circuit with appropriate overcurrent protection. Using a single, properly rated power strip with overload protection for a smaller number of lights.

Be Open to His Perspective

Listen to his reasoning for the way he did it. He might have thought he was being resourceful, but not understood the full implications.

Document the conversation

Write down the date you talked to him and what you said.2.

If the Maintenance Guy is Unreceptive or Refuses to Correct the Issue



Escalate to Your Manager/Supervisor Immediately

If the maintenance guy dismisses your concerns or refuses to correct the unsafe wiring, you must inform your manager or supervisor.

Explain the Severity

Clearly explain the potential safety hazards and code violations to your manager. Emphasize the risk of fire, electrical shock, and potential liability for the company.

Provide Specifics

Be prepared to provide details about the wiring setup, including the number of lights, the type of cord, the power strip used, and the location of the installation.

Document Everything

Document the date you informed your manager, what you told them, and their response.3.

Involve Safety Personnel (if applicable)

If your company has a dedicated safety officer or safety department, involve them as well. They will have the expertise to assess the situation and ensure that it's corrected safely and according to code.

Important Considerations



Your Responsibility

As an electrician, you have a professional and ethical responsibility to ensure electrical safety. You could be held liable if you knew about an unsafe condition and didn't take steps to correct it.

Company Policy

Be aware of your company's policies regarding safety reporting.

"Lock Out, Tag Out" (LOTO)

If the setup is actively being used and poses an immediate hazard, consider de-energizing the circuit and applying LOTO procedures to prevent anyone from using it until it's corrected. This should only be done if you are authorized to do so by your company and are familiar with LOTO procedures.

In summary:

Start by talking to the maintenance guy. If that doesn't resolve the issue, immediately inform your manager. The situation is unsafe and needs to be addressed promptly to prevent potential accidents and ensure code compliance. Flag for review