# EN 60745-1 手持式电动工具 安全 第1部分 通用要求 - 标准号：EN 60745-1　年份：2006　文件名状态：— - 来源 PDF：`安全标准\电动工具\BS EN 60745-1-2006 手持式电动工具 安全 第1部分 通用要求.pdf` - 页数：158　提取字符：342,921　页眉页脚过滤：1 条 - 文字层完整性：full（每页数字中位数 83.0）　语种：英文　小数：完整 719 / 疑似残缺 0 - 提取时间：2026-11-03　方式：文字层直提（未 OCR） - 正文可疑：否 > 本页眉之后是原文，按页排列。**表格线、图样、尺寸标注在纯文本里会走形，判定试验参数时以 PDF 原件为准。** BRITISH STANDARD BS EN 60745-1:2006 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Hand-held motor-operated electric tools — Safety — Part 1: General requirements The European Standard EN 60745-1:2006 has the status of a British Standard ICS 25.140.20         BS EN 60745-1:2006 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI This British Standard was published under the authority of the Standards Policy and Strategy Committee on 29 December 2006 © BSI 2006 ISBN 0 580 49842 5 National foreword This British Standard was published by BSI. It is the UK implementation of EN 60745-1:2006. It was derived by CENELEC from IEC 60745-1:2006. It supersedes BS EN 60745-1:2003, which will be withdrawn on 1 June 2009. The CENELEC common modifications have been implemented at the appropriate places in the text and are indicated by tags (e.g. ). The UK participation in its preparation was entrusted by Technical Committee CPL/61, Safety of household and similar electrical appliances, to Subcommittee CPL/61/6, Portable motor-operated tools. A list of organizations represented on CPL/61/6 can be obtained on request to its secretary. This publication does not purport to include all the necessary provisions of a contract. Users are responsible for its correct application. Compliance with a British Standard cannot confer immunity from legal obligations. Amendments issued since publication Amd. No. Date Comments EUROPEAN STANDARD EN 60745-1 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI NORME EUROPÉENNE EUROPÄISCHE NORM August 2006 ICS 25.140.20 Supersedes EN 60745-1:2003 + A1:2003 English version Hand-held motor-operated electric tools - Safety Part 1: General requirements (IEC 60745-1:2006, modified) Outils électroportatifs à moteur - Sécurité Partie 1: Règles générales (CEI 60745-1:2006, modifiée) Handgeführte motorbetriebene Elektrowerkzeuge - Sicherheit Teil 1: Allgemeine Anforderungen (IEC 60745-1:2006, modifiziert) This European Standard was approved by CENELEC on 2006-06-01. CENELEC members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CENELEC member. This European Standard exists in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CENELEC member into its own language and notified to the Central Secretariat has the same status as the official versions. CENELEC members are the national electrotechnical committees of Austria, Belgium, Cyprus, the Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and the United Kingdom. CENELEC European Committee for Electrotechnical Standardization Comité Européen de Normalisation Electrotechnique Europäisches Komitee für Elektrotechnische Normung Central Secretariat: rue de Stassart 35, B - 1050 Brussels © 2006 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members. Ref. No. EN 60745-1:2006 E Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Foreword The text of document 61F/632/FDIS, future edition 4 of IEC 60745-1, prepared by SC 61F, Safety of hand-held motor-operated electric tools, of IEC TC 61, Safety of household and similar electrical appliances, was submitted to the IEC-CENELEC parallel vote. A draft amendment, prepared by the Technical Committee CENELEC TC 61F, Safety of hand-held and transportable motor-operated electric tools, was submitted to the formal vote. The combined texts were approved by CENELEC as EN 60745-1 on 2006-06-01. This European Standard supersedes EN 60745-1:2003 + A1:2003. The following dates were fixed: – latest date by which the EN has to be implemented at national level by publication of an identical (dop) 2007-06-01 – latest date by which the national standards conflicting with the EN have to be withdrawn (dow) 2009-06-01 European Commission and the European Free Trade Association and covers essential health and safety requirements of the Machinery Directive. Compliance with the clauses of Part 1 together with a Part 2 provides one means of conforming to the essential health and safety requirements of the Directive concerned. A relevant Part 2 is one in which the type of the tool or an accessory which is to be used with the tool is within the scope of that Part 2. When a relevant Part 2 does not exist, Part 1 can help to establish the requirements for the tool, but will not by itself provide a means of conforming to the relevant essential health and safety requirements of the Machinery Directive. Other standards referred to in this European Standard are also listed in Clause 2, which gives the valid edition of those documents at the time of issue of this EN. CEN Technical Committees have produced a range of standards dealing with a similar range of non-electrically powered tools. Where necessary normative references are made to these standards in the relevant Part 2. This European Standard follows the overall requirements of EN ISO 12100-1 and EN ISO 12100-2. This European Standard is divided into two parts: Part 1: General requirements which are common to most hand-held electric motor operated tools (for the purpose of this standard referred to simply as tools) which could come within the scope of this standard; Part 2: Requirements for particular types of tools which either supplement or modify the requirements given in Part 1 to account for the particular hazards and characteristics of these specific tools. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI NOTE In this standard the following print types are used: - requirements proper; in roman type - test specifications: in italic type; - explanatory matter: in smaller roman type. EN 60745-1:2006 Subclauses, tables and figures which are additional to those in IEC 60745-1 are prefixed “Z”. Endorsement notice The text of the International Standard IEC 60745-1:2006 was approved by CENELEC as a European Standard with agreed common modifications. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI CONTENTS INTRODUCTION ................................................................................................................. H7 Scope ........................................................................................................................... H8 Normative references .................................................................................................... H9 Terms and definitions .................................................................................................. H12 General requirements .................................................................................................. H18 General conditions for the tests ................................................................................... H18 Void .............................................................................................................................20 Classification............................................................................................................... H30 Marking and instructions.............................................................................................. H31 Protection against access to live parts ......................................................................... H39 10 Starting ....................................................................................................................... H41 11 Input and current ......................................................................................................... H41 12 Heating ....................................................................................................................... H41 13 Leakage current .......................................................................................................... H45 14 Moisture resistance ..................................................................................................... H46 15 Electric strength .......................................................................................................... H49 16 Overload protection of transformers and associated circuits......................................... H51 17 Endurance................................................................................................................... H51 18 Abnormal operation ..................................................................................................... H52 19 Mechanical hazards..................................................................................................... H57 20 Mechanical strength .................................................................................................... H58 21 Construction................................................................................................................ H59 22 Internal wiring ............................................................................................................. H67 23 Components................................................................................................................ H68 24 Supply connection and external flexible cords.............................................................. H70 25 Terminals for external conductors ................................................................................ H76 26 Provision for earthing .................................................................................................. H79 27 Screws and connections .............................................................................................. H81 28 Creepage distances, clearances and distances through insulation ............................... H84 29 Resistance to heat, fire and tracking............................................................................ H87 30 Resistance to rusting................................................................................................... H89 31 Radiation, toxicity and similar hazards ......................................................................... H90 Annex A (normative) Measurement of creepage distances and clearances ...................... H101 Annex B (normative) Motors not isolated from the supply mains and having basic insulation not designed for the rated voltage of the tool .................................................... H106 Annex C Void .................................................................................................................. H108 Annex D Void .................................................................................................................. H109 Annex E Void................................................................................................................... H110 Annex F (normative) Needle-flame test ........................................................................... H111 Annex G (normative) Proof tracking test.......................................................................... H112 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex H Void .................................................................................................................. H113 Annex I (normative) Switches.......................................................................................... H114 Annex J (informative) Selection and sequence of the tests of Clause 29 .......................... H117 Annex K (normative) Battery tools and battery packs...................................................... H118 Annex L (normative) Battery tools and battery packs provided with mains connection or non-isolated sources ................................................................................................... H129 Annex M (normative) Safety of working stands for operation with hand-held motor- operated electric tools ..................................................................................................... H140 Annex N (informative) Rules for routine tests .................................................................. H147 Annex ZA (normative) Normative references to international publications with their corresponding European publications .............................................................................. H150 Annex ZB (informative) Possible sources of errors during vibration measurements .......... H154 Bibliography .................................................................................................................... H149 Figure 1 – Standard test finger........................................................................................... H91 Figure 2 − Test pin ............................................................................................................ H92 Figure 3 − Diagram for leakage current measurement at operating temperature for single-phase connection and three-phase tools suitable for single-phase supply ................ H92 Figure 4 − Diagram for leakage current measurement at operating temperature for three-phase connection ..................................................................................................... H93 Figure 5 − Ball-pressure test apparatus.............................................................................. H93 Figure 6 − Schematic representation of cord anchorages ................................................... H94 Figure 7 – Test fingernail ................................................................................................... H95 Figure 8 – Examples of parts of earthing terminals ............................................................. H96 Figure 9 − Flexing test apparatus....................................................................................... H97 Figure 10 – Circuit for measuring leakage currents ............................................................ H98 Figure 11 – Example of an electronic circuit with low-power points ..................................... H98 Figure Z1 – Test bench.......................................................................................................99 Figure Z2 – Positions of power tool and microphones for the hemispherical/cylindrical measurement surface .........................................................................................................99 Figure Z3 – Directions of vibration measurement...............................................................100 Figure A.1a – Clearance gap for parallel sided and V-shaped groove ............................... H102 Figure A.1b – Clearance gap for rib and uncemented joint with groove ............................. H103 Figure A.1c – Clearance gap for uncemented joint and diverging-sided groove ................. H104 Figure A.1d – Clearance gap between wall and screw ...................................................... H105 Figure B.1 – Simulation of defects ................................................................................... H107 Figure K.1 – Measurement of clearances ......................................................................... H128 Figure L.1 – Measurement of clearances.......................................................................... H139 Table 1 – Maximum normal temperature rises .................................................................... H43 Table 2 – Test voltages ..................................................................................................... H50 Table 3 – Maximum winding temperature ........................................................................... H54 Table 4 – Impact energies ................................................................................................. H58 Table 5 – Test torques....................................................................................................... H59 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Table 6 – Minimum cross-sectional area of supply cord...................................................... H71 Table 7 – Pull and torque value.......................................................................................... H74 Table 8 – Nominal cross-sectional area of conductors........................................................ H78 Table 9 – Torque for testing screws and nuts ..................................................................... H83 Table 10 – Minimum creepage distances and clearances ................................................... H85 Table K.1 – Maximum normal temperature rises for battery tools ...................................... H122 Table K.2 – Minimum creepage distances and clearances between parts of opposite polarity ............................................................................................................................ H127 Table L.1 – Minimum creepage distances and clearances between parts of opposite polarity ............................................................................................................................ H137 Table N.1 – Test voltages for the electric strength test ..................................................... H148 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI INTRODUCTION Individual countries may wish to consider the application of this Part 1 of IEC 60745, so far as is reasonable, to tools not mentioned in an individual part 2 and to tools designed on new principles. If the functions of a tool are covered by the different parts 2 of IEC 60745, the relevant part 2 is applied to each function separately, so far as is reasonable. If applicable, the influence of one function on the other is taken into account. A product employing materials or having forms of construction differing from those detailed in the requirements of this standard may be examined and tested according to the intention of the requirements and, if found to be substantially equivalent, may be judged to comply with the standard. Standards dealing with non-safety aspects of hand-held tools are: – IEC standards published by TC 59 on methods of measuring performance; – CISPR 11 and 14 on radio interference suppression; – IEC 61000-3-2 and IEC 61000-3-3 on electromagnetic compatibility. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI HAND-HELD MOTOR-OPERATED ELECTRIC TOOLS – SAFETY – Part 1: General requirements Scope This part of IEC 60745 deals with the safety of hand-held motor-operated or magnetically driven electric tools, the rated voltage of the tools being not more than 250 V for single-phase a.c. or d.c. tools, and 440 V for three-phase a.c. tools. So far as is practicable, this standard deals with the common hazards presented by hand- held tools which are encountered by all persons in the normal use and reasonably foreseeable misuse of the tools. Tools with an electric heating element are within the scope of this standard. They should also comply with relevant parts of IEC 60335. Requirements for motors not isolated from the supply, and having basic insulation not designed for the rated voltage of the tools, are given in Annex B. Requirements for rechargeable battery-powered motor-operated or magnetically driven tools and the battery packs for such tools are given in Annex K. Those for such tools that are also operated and/or charged directly from the mains or a non-isolated source are given in Annex L. Hand-held electric tools, hereinafter referred to as tools, which can be mounted on a support or working stand for use as fixed tools without any alteration of the tool itself, are within the scope of this standard. Requirements for such supports or working stands are given in Annex M. This standard does not apply to: – hand-held tools intended to be used in the presence of explosive atmosphere (dust, vapour or gas); – hand-held tools used for preparing and processing food; – hand-held tools for medical purposes (IEC 60601); – heating tools which are covered by IEC 60335-2-45. For hand-held tools intended to be used in vehicles or on board ships or aircraft, additional requirements may be necessary. For hand-held tools intended to be used in tropical countries, special requirements may be necessary. NOTE Attention is drawn to the fact that in many countries, additional requirements are specified by the national health authorities, the national authorities responsible for the protection of labour, the national water supply authorities, etc. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Normative references The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. IEC 60061-DB F1):2005, Lamp caps and holders together with gauges for the control of interchangeability and safety IEC 60065:2001, Audio, video and similar electronic apparatus – Safety requirements IEC 60068-2-75:1997, Environmental testing – Part 2: Tests – Test Eh: Hammer tests IEC 60085, Electrical insulation – Thermal classification IEC 60112:2003, Method for the determination of the proof and the comparative tracking indices of solid insulating materials IEC 60127-3, Miniature fuses – Part 3: Sub-miniature fuse-links IEC 60227 (all parts), Polyvinyl chloride insulated cables of rated voltages up to and including 450/750 V IEC 60245 (all parts), Rubber insulated cables – Rated voltages up to and including 450/750 V IEC 60309 (all parts), Plugs, socket-outlets and couplers for industrial purposes IEC 60320 (all parts), Appliance couplers for household and similar general purposes IEC 60335-1:2001, Safety of household and similar electrical appliances – Part 1: General requirements Amendment 1 (2004) F2 IEC 60384-14, Fixed capacitors for use in electronic equipment – Part 14: Sectional specification: Fixed capacitors for electromagnetic interference suppression and connection to the supply mains IEC 60417-DB F3):2002, Graphical symbols for use on equipment IEC 60529:1989, Degrees of protection provided by enclosures (IP Code) Amendment 1 (1999) F4 _________ 1) ‘DB’ refers to the on-line IEC database. 2) A consolidated edition (4.1) exists including IEC 60335-1:2001 and its Amendment 1 (2001). 3) ‘DB’ refers to the on-line IEC database. 4) A consolidated edition (2.1) exists including IEC 60529:1989 and its Amendment 1 (1999). Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI IEC 60695-2-11, Fire hazard testing – Part 2-11: Glowing/hot-wire based test methods – Glow-wire flammability test method for end-products IEC 60695-11-5:2004, Fire hazard testing – Part 11-5: Test flames – Needle-flame test method – Apparatus, confirmatory test arrangement and guidance IEC 60695-11-10, Fire hazard testing – Part 11-10: Test flames – 50 W horizontal and vertical flame test methods IEC 60730-1:1999, Automatic electrical controls for household and similar use – Part 1: General requirements Amendment 1 (2003) F5 IEC 60760, Flat, quick connect terminations IEC 60825-1, Safety of Laser Products – Part 1: Equipment classification, requirements and user’s guide IEC 60884 (all parts), Plugs and socket-outlets for household and similar purposes IEC 60998-2-1, Connecting devices for low-voltage circuits for household and similar purposes – Part 2-1: Particular requirements for connecting devices as separate entities with screw-type clamping units IEC 60998-2-2, Connecting devices for low-voltage circuits for household and similar purposes – Part 2-2: Particular requirements for connecting devices as separate entities with screwless-type clamping units IEC 60999-1:1999, Connecting devices – Electrical copper conductors – Safety requirements for screw-type and screwless-type clamping units – Part 1: General requirements and particular requirements for clamping units for conductors from 0,2 mm2 up to 35 mm2 (included) IEC 61058-1:2000, Switches for appliances – Part 1: General requirements Amendment 1 (2001) F6 IEC 61540:1997, Electrical accessories – Portable residual current devices without integral overcurrent protection for household and similar use (PRCDs) Amendment 1 (1998) F7 IEC 61558-1, Safety of power transformers, power supplies, reactors and similar products – Part 1: General requirements and tests ISO 1463, Metallic and oxide coatings – Measurement of coating thickness – Microscopical method ISO 2178, Non-magnetic coatings on magnetic substrates – Measurement of coating thickness – Magnetic method _________ 5) A consolidated edition (3.1) exists including IEC 60730-1:1999 and its Amendment 1 (2003). 6) A consolidated edition (3.1) exists including IEC 61058-1:2000 and its Amendment 1 (2001). 7) A consolidated edition (1.1) exists including IEC 61540:1997 and its Amendment 1 (1998). Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI ISO 3864-2, Graphical symbols – Safety colours and safety signs – Part 2: Design principles for product safety labels ISO 7010, Graphical symbols – Safety colours and safety signs – Safety signs used in workplaces and public areas ISO 9772, Cellular plastics – Determination of horizontal burning characteristics of small specimens subjected to a small flame CR 1030-1:1995, Hand-arm vibration – Guidelines for vibration hazards reduction – Part 1: Engineering methods by design of machinery EN 12096:1997, Mechanical vibration - Declaration and verification of vibration emission values EN 27574-4:1988, Acoustics - Statistical methods for determining and verifying stated noise emission values of machinery and equipment - Part 4: Methods for stated values for batches of machines (ISO 7574-4:1985) EN ISO 8041:2005, Human response to vibration - Measuring instrumentation (ISO 8041:2005) EN ISO 3744:1995, Acoustics - Determination of sound power levels of noise sources using sound pressure - Engineering method in an essentially free field over a reflecting plane (ISO 3744:1994) EN ISO 4871:1996, Acoustics - Declaration and verification of noise emission values of machinery and equipment (ISO 4871:1996) EN ISO 5349 (all parts), Mechanical vibration -- Measurement and evaluation of human exposure to hand-transmitted vibration (ISO 5349 all parts) EN ISO 11203:1995, Acoustics - Noise emitted by machinery and equipment - Determination of emission sound pressure levels at a work station and at other specified positions from the sound power level (ISO 11203:1995) EN ISO 11688-1:1998, Acoustics - Recommended practice for the design of low noise machinery and equipment - Part 1: Planning (ISO/IR 11688-1:1995) EN ISO 11690-3:1998, Acoustics - Recommended practice for the design of low-noise workplaces containing machinery - Part 3: Sound propagation and noise prediction in workrooms (ISO/TR 11690-3:1997) EN ISO 20643:2005, Mechanical vibration - Hand-held and hand-guided machinery - Principles for evaluation of vibration emission (ISO 20643:2005) ISO 5347 (all parts), Methods for the calibration of vibration and shock pick-ups ISO 16063-1:1998, Methods for the calibration of vibration and shock transducers - Part 1: Basic concepts Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Terms and definitions For the purposes of this document, the following terms and definitions apply. Where the terms voltage and current are used, they imply the r.m.s. values, unless otherwise specified. Where in this standard the expressions “with the aid of a tool”, “without the aid of a tool”, and “requires the use of a tool”, are used, the word “tool” means a hand tool, for example a screwdriver, which may be used to operate a screw or other fixing means. 3.1 accessible part part which can be touched by means of the standard test finger in Figure 1, including, for accessible metal parts, any metal part connected to it 3.2 accessory device that is attached only to the output mechanism of the tool 3.3 all-pole disconnection disconnection of all supply conductors except the protective earthing (grounding) conductor by a single initiating action 3.4 attachment device attached to the housing or other component of the tool and which may or may not be attached to the output mechanism and does not modify the normal use of the tool within the scope of this standard 3.5 basic insulation insulation, not necessarily including insulation used for functional purposes, applied to live parts to provide basic protection against electric shock 3.6 class I tool tool in which protection against electric shock does not rely on basic, double or reinforced insulation only, but which includes an additional safety precaution in that conductive accessible parts are connected to the protective earthing conductor in the fixed wiring of the installation in such a way that conductive accessible parts cannot become live in the event of a failure of the basic insulation. Also considered as class I tools are tools with double insulation and/or reinforced insulation throughout having an earthing terminal or earthing contact Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 3.7 class II tool tool in which protection against electric shock does not rely on basic insulation only, but in which additional safety precautions, such as double insulation or reinforced insulation, are provided, there being no provision for protective earthing or reliance upon installation conditions 3.8 class III tool tool in which protection against electric shock relies on supply at safety extra-low voltage, and in which voltages higher than those of safety extra-low voltages are not generated 3.9 class II construction part of a tool for which protection against electric shock relies upon double insulation or reinforced insulation 3.10 class III construction part of a tool for which protection against electric shock relies upon safety extra-low voltage, and in which voltages higher than those of safety extra-low voltages are not generated 3.11 clearance shortest distance between two conductive parts, or between a conductive part and the outer surface of the enclosure, considered as though metal foil were pressed into contact with accessible surfaces of insulating material, measured through air NOTE Examples of clearance distances are given in Annex A. 3.12 creepage distance shortest path between two conductive parts, or between a conductive part and the outer surface of the enclosure, considered as though metal foil were pressed into contact with accessible surfaces of insulating material, measured along the surface of the insulating material NOTE Examples of creepage distances are given in Annex A. 3.13 detachable cord flexible cord, for supply, intended to be connected to the tool by means of a suitable appliance coupler 3.14 detachable part part which can be removed or opened without the aid of a tool, or a part which is removed in accordance with the instruction for use, except user maintenance items, even if removal requires the use of a tool 3.15 double insulation insulation system comprising both basic insulation and supplementary insulation 3.16 electronic circuit circuit incorporating at least one electronic component Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 3.17 electronic component part in which conduction is achieved principally by electrons moving through a vacuum, gas or semiconductor, with the exclusion of neon indicators 3.18 exchange type tool tool which is intended not to be repaired at all, or to be repaired by the manufacturer's service organization only 3.19 extra-low voltage voltage supplied from a source within the tool and, which, when the tool is supplied at rated voltage, does not exceed 50 V between conductors and between conductors and earth 3.20 extra-severe duty conditions of insulating material where there is heavy deposition of conductive material and a long period of electrical stress; or an extra heavy deposition of conductive material and a short period of electrical stress 3.21 hand-held tool (in this standard abbreviated to “tool”) electric motor-operated or magnetically-driven machine intended to do mechanical work, with or without provisions for mounting on a support, and so designed that the motor and the machine form an assembly which can easily be brought to the place of operation, and which is either held or supported by hand or suspended during operation NOTE Hand-held tools may be provided with a flexible shaft, the motor being either fixed or portable. 3.22 intermittent operation operation in a series of specified identical cycles, each cycle being composed of a period of operation under normal load followed by a rest period with the tool running idle or switched off 3.23 liquid system system that employs water or a water-based liquid from an external or integral supply that is necessary to complete the intended function of the tool 3.24 live part any conductor or conductive part intended to be energized in normal use, including a neutral conductor but, by convention, not a PEN conductor. 3.25 no-load input / current highest input or current obtained when a tool is operated at rated voltage and frequency with manufacturer and adjusted according to manufacturer’s instructions, ready for use 3.26 non-detachable part part which can only be removed or opened with the aid of a tool, or a part which fulfils the test of 21.22 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 3.27 non-self-resetting thermal cut-out thermal cut-out which requires a manual operation for resetting, or replacement of a part, in order to restore the current 3.28 normal duty conditions of insulating material where there is virtually no deposition of conductive material and a long period of electrical stress; or a light deposition of conductive material and a short period of electrical stress 3.29 normal load load to be applied to a tool at rated voltage or at the upper limit of the rated voltage range, to obtain rated input or rated current, any marking of short-time or intermittent operation being observed and, unless otherwise specified, heating elements, if any, being operated as in normal use 3.30 normal use use of a tool for which it is designed, taking into account the manufacturer’s instructions 3.31 protective device device the operation of which prevents a hazardous situation under abnormal operation conditions 3.32 protective impedance impedance connected between live parts and accessible conductive parts, and of value so that the current is limited to a safe value 3.33 rated current current assigned to the tool by the manufacturer. If no current rating is assigned to the tool, the rated current for the purpose of this standard is the current measured when the tool is operated under normal load 3.34 rated frequency frequency assigned to the tool by the manufacturer 3.35 rated frequency range frequency range assigned to the tool by the manufacturer, expressed by its lower and upper limits 3.36 rated input input in watts assigned to the tool by the manufacturer. If no input is assigned to the tool, the rated input for the purpose of this standard is the input measured when the tool is operated under normal load 3.37 rated input range input range in watts assigned to the tool by the manufacturer, expressed by its lower and upper limits Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 3.38 rated no-load speed no-load speed at rated voltage or at the upper limit of the rated voltage range assigned to the tool by the manufacturer 3.39 rated operating time operating time assigned to the tool by the manufacturer 3.40 rated voltage voltage assigned to the tool by the manufacturer. For three-phase supply, it is the voltage between phases 3.41 rated voltage range voltage range assigned to the tools by the manufacturer, expressed by its lower and upper limits 3.42 reinforced insulation insulation of hazardous live parts which provides a degree of protection against electric shock equivalent to double insulation NOTE Examples of reinforced insulation are a single layer or several layers which cannot be tested singly as basic insulation or supplementary insulation. 3.43 residual current device RCD device intended to detect a diversion of current from a circuit in a way that may expose the user to an electric shock; in such conditions the device opens the circuit NOTE Such a device is also known as portable residual current device (PRCD), ground fault circuit interrupter (GFCI) or earth leakage circuit breaker (ELCB). 3.44 routine servicing periodic servicing which requires tool disassembly as instructed by the instruction manual and performed by authorized service centre 3.45 safety extra-low voltage rated voltage not exceeding 42 V between conductors and between conductors and earth, the no-load voltage not exceeding 50 V. When safety extra-low voltage is obtained from the supply mains, it is to be through a safety isolating transformer or a convertor with separate windings, the insulation of which complies with double or reinforced insulation requirements 3.46 safety isolating transformer insulation at least equivalent to double insulation or reinforced insulation, and which is intended to supply a distribution circuit, a tool or other equipment at safety extra-low voltage 3.47 self-resetting thermal cut-out thermal cut-out which automatically restores the current after the relevant part of the tool has cooled down to a given value Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 3.48 severe duty conditions of insulating material where there is a light deposition of conductive material and a long period of electrical stress; or a heavy deposition of conductive material and a short period of electrical stress 3.49 short-time operation operation under normal load for a specified period, starting from cold, the intervals between each period of operation being sufficient to allow the tool to cool down approximately to ambient temperature 3.50 supplementary insulation independent insulation applied in addition to the basic insulation, in order to provide protection against electric shock in the event of a failure of the basic insulation 3.51 supply cord flexible cord, for supply purposes, which is fixed to the tool 3.52 temperature limiter temperature-sensing device, the operating temperature of which may be either fixed or adjustable, and which, during normal operation, operates by opening or closing a circuit when the temperature of the controlled part reaches a predetermined value. It does not make the reverse operation during the normal duty cycle of the tool 3.53 thermal cut-out device which, during abnormal operation, limits the temperature of the controlled part by automatically opening the circuit, or by reducing the current, and which is so constructed that its setting cannot be altered by the user 3.54 thermal link thermal cut-out which operates only once, and then requires partial or complete replacement 3.55 thermostat temperature-sensing device, the operating temperature of which may be either fixed or adjustable; and which, during normal operation, keeps the temperature of the controlled part between certain limits by automatically opening and closing a circuit 3.56 type X attachment method of attachment of the supply cord so that it can easily be replaced 3.57 type Y attachment method of attachment of the supply cord such that any replacement is intended to be made by the manufacturer, its service agent or similar qualified person Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 3.58 type Z attachment method of attachment of the supply cord so that it cannot be replaced without breaking or destroying the tool 3.59 user maintenance any maintenance operation stated in the instructions for use or marked on the tool which the manufacturer of the tool intends the user to perform 3.60 working voltage maximum voltage, without the effect of transient voltages, to which the part under consideration is subjected when the tool is supplied at its rated voltage and operating under normal load General requirements Tools shall be so constructed that in normal use they function safely so as to cause no danger to persons or surroundings, even in the event of reasonably foreseeable misuse. In general, this principle is achieved by fulfilling the relevant requirements specified in this standard, and compliance is checked by carrying out all the relevant tests. NOTE Annex N shows an example of routine tests. General conditions for the tests 5.1 Tests according to this standard are type tests. 5.2 Unless otherwise specified, the tests are made on a single tool, which shall withstand all the relevant tests. However, any test that requires tool modifications or disassembly after the test may be performed on a separate sample. Additional samples may be required, for example, if the tool is designed for different supply voltages. The testing of components may necessitate the submission of additional samples of these components. The cumulative stress resulting from successive tests on electronic circuits is to be avoided. It may be necessary to replace components or to use additional samples. The number of additional samples should be kept to a minimum by an evaluation of the relevant electronic circuits. 5.3 Unless otherwise specified, the tests are carried out in the order of the clauses. If it is evident from the construction of the tool that a particular test is not applicable, the test is not made. 5.4 The tests are carried out with the tool, or any movable part of it, placed in the most unfavourable position that may occur in normal use. 5.5 Tools provided with controls or switching devices are tested with these controls or devices adjusted to their most unfavourable settings, if the setting can be altered by the user. Electronic speed control devices are set for the highest speed. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI If the adjusting means of the control is accessible without the aid of a tool, this subclause applies whether the setting can be altered by hand or with the aid of a tool. If the adjusting means is not accessible without the aid of a tool, and if the setting is not intended to be altered by the user, this subclause does not apply. Adequate sealing is regarded as preventing alteration of the setting by the user. 5.6 The tests are made in a draught-free location and, in general, at an ambient temperature of (20 ± 5) °C. If the temperature attained by any part is limited by a temperature sensitive device, or is influenced by the temperature, the room temperature is, in case of doubt, maintained at (23 ± 2) °C. 5.7.1 Tools for a.c. only are tested with a.c. at rated frequency, if marked, and those for a.c./d.c. are tested at the more unfavourable supply. Tools for a.c. which are not marked with rated frequency, or marked with a frequency range of 50 Hz to 60 Hz, are tested with either 50 Hz or 60 Hz, whichever is the more unfavourable. 5.7.2 Tools having more than one rated voltage are tested on the basis of the most unfavourable voltage. When it is specified for tools marked with a rated voltage range that the supply voltage is equal to the rated voltage multiplied by a factor, the supply voltage is equal to: – the upper limit of the rated voltage range multiplied by this factor, if greater than 1; – the lower limit of the rated voltage range multiplied by this factor, if smaller than 1. When a factor is not specified, the supply voltage is the most unfavourable within the rated voltage range. For tools having more than one rated voltage or rated voltage range, it may be necessary to make some of the tests at the minimum, the mean, and the maximum values of the rated voltage, or the rated voltage range, in order to establish the most unfavourable voltage. 5.7.3 For tools marked with a rated voltage range and rated input corresponding to the mean of the rated voltage range, when it is specified that the power input is equal to rated input multiplied by a factor, the input is equal to: – the calculated input corresponding to the upper limit of the rated voltage range multiplied by this factor, if greater than 1: – the calculated input corresponding to the lower limit of the rated voltage range multiplied by this factor, if smaller than 1. When a factor is not specified, the input corresponds to the input at the most unfavourable rated voltage within the range. 5.8 When alternative attachments are made available for the tool by its manufacturer, the tool is tested with those attachments which give the most unfavourable results. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 5.9 Unless otherwise specified, tools are tested with the appropriate flexible cord connected to the tool. 5.10 If class I tools have accessible metal parts which are not connected to an earthing terminal or earthing contact, and are not separated from live parts by an intermediate metal part which is connected to an earthing terminal or earthing contact, such parts are checked for compliance with the appropriate requirements specified for class II construction. If class I tools have accessible non-metallic parts, such parts are checked for compliance with the appropriate requirements specified for class II construction, unless these parts are separated from live parts by an intermediate metal part connected to an earthing terminal or earthing contact. 5.11 If class I or class II tools have parts operating at safety extra-low voltage, such parts are checked for compliance with the appropriate requirements specified for class III tools. 5.12 When testing electronic circuits, the supply is to be free from those perturbations from external sources that can influence the results of the tests. 5.13 If, in normal use, the heating element cannot be operated unless the motor is running, the element is tested with the motor running. If the heating element can be operated without the motor running, the element is tested with or without the motor running, whichever is the more unfavourable. Heating elements incorporated in the tool are connected to a separate supply unless otherwise specified. 5.14 For attachments performing a function which is within the scope of one of the relevant parts 2, the tests are made in accordance with that part 2. For other attachments, the tests are made in accordance with manufacturer's instructions; in the absence of such instructions, the tool is operated continuously at a load at which rated input or rated current is attained. 5.15 If a torque is to be applied, the method of loading is chosen so as to avoid additional stresses, such as those caused by side thrust. Additional loads necessary for the correct operation of the tool are, however, taken into consideration. If a brake is used for applying a load, it must be applied gradually to assure that the starting current does not affect the test. Modification of output means for purpose of loading is permitted for the connection to a brake. 5.16 Tools intended to be operated at safety extra-low voltage are tested together with their supply transformer, if this is normally sold with the tool.  6 Environmental requirements 6.1 Noise 6.1.1 Noise reduction Noise reduction at tools is an integral part of the design process and shall be achieved by particularly applying measures at source to control noise, see for example EN ISO 11688-1. The success of the applied noise reduction measures is assessed on the basis of the actual noise emission values in relation to other machines of the same type with comparable non acoustical technical data. The major sound sources of tools are: motor, fan, gear. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 6.1.2 Noise test code (grade 2) 6.1.2.1 General 6.1.2.2 Sound power level determination ) ( pfA WA 10lg S with pfA L determined from ⎡ = ∑ ⎤ i pA, 10lg K K L 0,1 pfA L − − ⎥ ⎥ ⎦ ⎢ ⎢ ⎣ 2A 1A = i EN 60745-1:2006 Noise emission values like the emission sound pressure level pA L and the sound power level WA L to be quoted in the user instructions as required by 8.12.2 Za)1) shall be measured according to the test procedure described in 6.1.2.1 to 6.1.2.6. The overall noise can be divided into the pure machine noise and the noise of processing the workpiece. Both are influenced by the method of operation, however for percussive tools the noise emission of the workpiece can be dominant. The load conditions for particular tools are therefore specified in the relevant Part 2. Noise emission values obtained under these measurement conditions will not necessarily correspond to the noise levels produced under the operational conditions of practical use. NOTE It is not possible to simulate all conditions of practical use. A statement of process noise could therefore - be misleading and cause faulty assessment of the risk in individual cases, - discourage the development of more silent machines, - lead to low repeatability of measurements and thus cause problems when verifying declared noise values, - make the comparison of the noise emission from different tools difficult. The sound power level shall be measured according to EN ISO 3744, where the acoustic environment, instrumentation, quantities to be measured, quantities to be determined, and the measurement procedure are specified. The sound power level shall be given as A-weighted sound power level in dB reference 1 pW. The A-weighted sound pressure levels, from which the sound power is to be determined, shall be measured directly, and not calculated from frequency band data. Measurements shall be made in an essentially free field over a reflecting plane. For all hand-held electric power tools, the sound power level shall be determined by using a hemispherical / cylindrical measurement surface according to Figure Z2. The hemispherical / cylindrical measurement surface is described by a hemisphere standing on a cylindrical pedestal (see Figure Z2). Five microphone positions shall be located 1 m from the geometric centre of the power tool. Four positions shall be spaced at regular intervals on a plane defined as passing through the geometric centre of the power tool and parallel to the reflecting plane; the fifth position shall be located at a distance of 1 m above geometric centre of the power tool. The A-weighted sound power level, WA L , shall be calculated, in accordance with Subclause 8.6 of EN ISO 3744 as follows : S L L + = , in dB (Z1) ′  Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI where 1A K Background noise correction, A-weighted 2A K Environmental correction, A-weighted S Area of the measurement surface, in m2 S = 1 m2 where and Therefore, m 4 π = S , so, from equation (Z1) 6.1.2.3 Emission sound pressure level determination where Q = 11, in dB LpA1 = LpA + 20 lg ) ( 1r , in dB EN 60745-1:2006 pfA L is the A-weighted surface sound pressure level according to EN ISO 3744 i pA, L′ A-weighted sound pressure level measured at the ith microphone position, in dB For the hemispherical / cylindrical measurement surface shown in Figure Z2, the area S of the measurement surface is calculated as follows: ) ( Rd R S + = π , in m2. (Z2) d = 1 m is the height of the distance of the geometrical centre of the power tool above the reflecting plane R = 1 m is the radius of the hemisphere and of the cylinder which comprise the measurement surface. pfA WA + = L L , in dB. (Z3) The A-weighted emission sound pressure level at the work station, LpA, shall be determined in accordance with EN ISO 11203 as follows: Q L L − = WA pA , in dB (Z4) NOTE 1 This value of Q has been determined, during experimental investigations, to be applicable to hand-held power tools. The resulting A-weighted emission sound pressure level at the workstation is equivalent to the value of the surface sound pressure level at a distance of 1 m from the power tool. This distance has been chosen to give satisfactory reproducibility of results, and to permit comparison of the acoustic performance of different hand-held power tools which do not, in general, have uniquely defined work stations. Under free field conditions, where it may be required to estimate the emission sound pressure level, LpA1, at a distance r1 in m from the geometric centre of the power tool, this may be done by applying the formula : NOTE 2 At any given position in relation to a particular machine, and for given mounting and operating conditions, the emission sound pressure levels determined by the method of this European Standard will in general be lower than the directly measured sound pressure levels for the same machine in the typical workroom where it is used. This is due to the influence of sound reflecting surfaces in the workroom compared to the free field conditions of the test specified here. A method of calculating the sound pressure levels in the vicinity of a machine operating alone in a workroom is given in EN ISO 11690-3. Commonly observed differences are 1 dB to 5 dB, but in extreme cases the difference may be even greater. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI If required, the C-weighted peak emission sound pressure level LpCpeak shall be measured at each of the five measurement positions specified in 6.1.2.2. The C-weighted peak emission sound pressure level at the work station is the highest C-weighted peak sound pressure level measured at any of the five microphone positions; no corrections are permitted. 6.1.2.4 Installation and mounting conditions of the power tools during noise tests The installation and mounting conditions shall be the same for the determination of both sound power level and emission sound pressure level at the work station. The power tool under test shall be new and equipped with accessories which affect the acoustic properties, as recommended by the manufacturer. Prior to commencing testing, the power tool (including any required ancillary equipment) shall be set up in a stable condition in accordance with the manufacturer’s instructions for safe use. The tool is held by the operator or suspended in such a way as to correspond to normal use, as specified in the relevant Part 2. If the power tool is used horizontally, it shall be positioned so that its axis is at 45o between the microphone positions 1 - 4 and 2 - 3; its geometrical centre shall be 1 m above the ground (reflecting plane). If these requirements are impracticable or the tool is not used horizontally, the adopted positions shall be recorded and described in the test report. The operator shall not be positioned directly between any microphone position and the power tool. 6.1.2.5 Operating conditions The operating conditions shall be identical for the determination of both sound power level and emission sound pressure level at the work station. Measurements shall be carried out on a new tool. Tools are tested under the two operating conditions “no load” or “load” as appropriate for the type of tool and specified in the relevant Part 2. Before starting the test, the tool shall be operated under these conditions for a period of at least 1 min. A measurement under “load” is to be carried out during processing of a workpiece or under external mechanical load equivalent to normal operation. Where tests are required to be carried out on a bench it shall be in accordance with the test bench shown in Figure Z1. Care shall be taken that the location of the work piece on its support does not adversely affect the result of the test. If necessary, or when specified in the Part 2, the work piece shall be supported on a resilient material 20 mm thick compressed to 10 mm under the weight of the work piece. Three consecutive tests for no-load or five for load shall be carried out and the result of the test LWA shall be the arithmetic mean, rounded to the nearest decibel, of the three or five tests. During measurements, the power tool shall operate under stable conditions. Once the noise emission is steady, the measurement time interval shall be at least 15 s, unless the operating conditions specified in the relevant Part 2 do not require another time interval. If measurements are to be made in octave or one-third octave frequency bands, the minimum period of observation shall be 30 s for the frequency bands centred on or below 160 Hz, and 15 s for the frequency bands centred on or above 200 Hz. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 6.1.2.6 Measurement uncertainties A standard deviation of reproducibility of less than 1,5 dB is expected for the A-weighted sound power level determined according to EN ISO 3744 and the A-weighted emission sound pressure level determined according to EN ISO 11203. 6.1.2.7 Information to be recorded The information to be recorded covers all of the technical requirements of this noise test code. Any deviations from this noise test code or from the basic standards upon which it is based are to be recorded together with the technical justification for such deviations. 6.1.2.8 Information to be reported The information to be included in the test report is at least that which is required to prepare a noise declaration or to verify the declared values. Thus as a minimum the following information shall be included: reference to this noise test code and to the basic standards used; description of the power tool; description of the mounting and operating conditions; the noise emission values obtained. It shall be confirmed that all requirements of the noise test code have been fulfilled, or, if this is not the case, any unfulfilled requirements shall be identified. Deviations from the requirements shall be stated and technical justification for the deviations shall be given. 6.1.2.9 Declaration and verification of noise emission values The declaration of the noise emission values shall be a dual number according to EN ISO 4871. It shall declare the noise emission value L (LpA, LpCpeak and LWA) and separately the respective uncertainty K (KpA, KpCpeak and KWA). For a standard deviation of reproducibility of 1,5 dB and for a typical standard deviation of production, the values for the uncertainty, KpA, KpCpeak and KWA respectively, are expected to be 3 dB. The noise declaration shall state that the noise emission values have been obtained according to this noise test code. If this statement is not true, the noise declaration shall indicate clearly what the deviations from this standard, and from the basic standards, are. NOTE If the measured value is the average based on a sample of three power tools that has been properly sampled, then K normally is 3 dB. Further guidance on sampling and uncertainty terms is given in EN 27574-4 and EN ISO 4871. Additional noise emission quantities may also be given in the declaration. If undertaken, the verification shall be performed for a batch of power tools, in accordance with Subclause 6.3 of EN ISO 4871. The verification shall be conducted by using the same mounting, installation and operating conditions as those used for the initial determination of noise emission values. 6.2 Vibration 6.2.1 Vibration reduction The vibration at the handles shall be kept as low as possible without unduly affecting the performance and the ergonomics (weight, handling, etc.) of the tool. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 6.2.2 Vibration measurement - General 6.2.3 Symbols In this subclause, the following symbols are used. σR standard deviation of reproducibility K uncertainty of ah in m/s2 N V a s C − = hv where N ∑ hv hvi N ) ( N = − − − = i EN 60745-1:2006 In particular vibration shall be reduced by the application of engineering measures as given in CR 1030-1. The success of the applied vibration measures is assessed by comparing the vibration levels for the tool with those for other tools of the same type and with a comparable specification and performance. Details for particular types of tools are given in the relevant Part 2. The test code gives all the information necessary to carry out efficiently the determination, declaration and verification of the vibration emission characteristics. It shall allow comparison of test results for different tools. EN 12096 gives guidance on how to declare the vibration emission values of machinery, and specifies requirements for verification of declared values. The vibration levels for hand-arm vibration ah to be quoted in the user instructions, as required by 8.12.2 Za)3) shall be measured in accordance with the following test procedure. The uncertainty K is provided as an indication of the measured deviation from the mean during the test. The measurement and assessment of human exposure to hand-transmitted vibration in the workplace is given in EN ISO 5349-1 and EN ISO 5349-2. NOTE Annex ZB provides information on possible sources of errors of measurement. ahw(t) instantaneous single-axis acceleration value of the frequency-weighted hand- transmitted vibration at time t, in m/s² ahw root-mean-square (r.m.s.) single-axis acceleration value of the frequency- weighted hand-transmitted vibration, in m/s² ahwx, ahwy, ahwz values of ahw in m/s², for the axes denoted X, Y and Z respectively ahv vibration total value of frequency-weighted r.m.s. acceleration, in m/s²; it is the root-sum-of-squares of the ahw values for the three measured axes of vibration ah arithmetic mean total vibration value of the measurement results of all runs and operators in m/s², this is the result of the test CV coefficient of variation of a test series, defined as the ratio of the standard deviation of a series of measurement values and the mean value of the series: a a s is the standard deviation hv a is the mean vibration total value of the series of 5 measurements in m/s² hvi a is the i-th vibration total value of one series of measurements in m/s² N is the number of measured values within one series of measurements (here N = 5) Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 6.2.4 Characterisation of vibration 6.2.4.1 Direction of measurement 6.2.4.2 Location of measurement NOTE 2 The above paragraph is under review. 6.2.4.3 Magnitude of vibration / T ⎤ ⎥ ⎥ ⎦ ⎢ ⎢ ⎣ ) ( a T a EN 60745-1:2006 Vibration transmitted to the hand is related to the three orthogonal directions X, Y and Z as shown in Figure Z3. For particular types of tools, these directions may be defined in the relevant Part 2. Measurements shall be made in three directions at each hand position. All measurements shall be conducted simultaneously. Measurements shall be carried out as close as possible to the hand between the thumb and the index finger, where an operator normally holds the machine. If gripping areas are covered by soft surface material, precaution shall be taken to avoid resonance effects of the transducer mounting. If soft surface material is provided in the gripping area it shall be removed or strongly compressed by a transducer mounting clamp or suitable adaptor. In the case of vibration isolated handles the location of measurement can influence the vibration significantly. If the transducer cannot be placed half way along the length of the handle, the points of measurement shall be left and right to the hand to determine the relevant vibration over the gripping area (see Figure Z3a). In this case, the test result for this handle is the average of the results of these two measurement positions. NOTE 1 E.g. at vibration-isolated handles of grinding machines, the vibration changes significantly over the length of the gripping zone. The measurement positions for particular types of tools are specified in the relevant Part 2. When machines are operated with more than one grip or grasping surface, the vibration at the hand positions where an operator normally holds the tool during normal operation shall be measured and recorded. If it can be shown that the vibration magnitude at one grip is always dominant, the vibration test code may specify that measurements are made only at that gripping zone. The quantity used to describe the magnitude of vibration shall be the frequency-weighted acceleration ahw in m/s². Frequency weighting in accordance with EN ISO 5349-1 shall be used. The r.m.s. value ahw in accordance with this European Standard is defined as the r.m.s. value of the frequency-weighted acceleration signal ahw(t): ⎡ = ∫ dt t hw hw (Z5) An integrating device equipped with linear integration facilities shall be used in order to obtain r.m.s. values of signals substantially varying with time. The measurement time shall be as long as reasonably possible and normally not less than 8 s for hand-transmitted vibration measurements. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 6.2.4.4 Combination of vibration directions The vibration total value ahv is determined from [ ] hwz hwy hwx hv where 6.2.5 Instrumentation requirements 6.2.5.1 General 6.2.5.2 Transducers 6.2.5.2.1 Specification of transducers 6.2.5.2.2 Fastening of transducers 6.2.5.3 Calibration of the measurement chain EN 60745-1:2006 If the measurement time of 8 s for individual machines is not possible, e.g. because of short duration of operation (defined in 6.2.6.3), this shall be specified in the relevant Part 2 of this standard. / a a a a + + = (Z6) ahwx, ahwy, ahwz are the r.m.s. values of the frequency-weighted acceleration in the directions X, Y and Z, respectively. The vibration measurement equipment shall be in accordance with EN ISO 8041. Instrumentation for measuring other parameters (e.g. for controlling the working conditions), whose characteristics are not covered by EN ISO 8401, shall be specified in the relevant Part 2. The vibration values as specified in 6.2.4.3 shall be measured using transducers and other appropriate measurement equipment conforming to EN ISO 8041. The total mass of the vibration transducer and its mounting shall not be sufficient to influence the measurement result and shall not be more than 5 g for each direction of measurement. NOTE Lightweight plastic handles are an example, where heavy transducers may not be suitable. See EN ISO 5349-2 for further information. Factors such as the transverse sensitivity (less than 10 %), the ambient temperature range, the typical temperature transient sensitivity and the maximum shock acceleration shall be considered in the selection of transducers. Guidance on mounting of transducers is given in EN ISO 5349-2. The transducer and the mechanical filter, if used, shall be mounted rigidly and on the vibrating surface. Mechanical filters or other appropriate means may be needed to minimize measurement errors likely to occur when measuring vibration containing impulsive elements, such as occur in percussive tools. For more details, see EN ISO 5349-2. NOTE High acceleration in the high-frequency components of the vibration can cause the transducer to generate false signals (e.g. dc shift) in the frequency range of interest because of excitation of the resonance of the transducer itself. The whole measurement system shall be checked both before and after a sequence of measurements using a calibrator which produces a known acceleration at a known frequency. The transducers shall be calibrated in accordance with ISO 5347 and ISO 16063-1. The whole measurement system shall be checked according to the requirements in EN ISO 8041. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 6.2.6 Testing and operating conditions of the machinery 6.2.6.1 General Measurements shall be carried out on a new tool that is only used for the noise and vibration tests required by this standard. When the test procedure is not provided in a relevant Part 2 or there is no relevant Part 2, the operating conditions and working procedure shall be specified in sufficient detail as to achieve appropriate reproducibility. Test procedures based on a typical real working situation are preferred. The vibration test may simulate a single phase of a task or a working cycle, consisting of a set of operations where the operator is being exposed to vibration. If for reasons of better reproducibility a simulated work condition is defined, the vibration source shall produce approximately the same magnitude of vibration as that in a typical working situation. If necessary to provide realistic emission levels, tests shall be carried out under more than one operating condition or set of operating conditions as defined in the relevant Part 2. If the machinery is equipped with means or devices to reduce the vibration emission in comparable operating conditions, these shall be used, in accordance with the user instructions, during vibration testing. If this requires a deviation from the type test method, this shall be reported and explained in the test report. During the measurements the hands of the operator shall guide the machine as is necessary by the design of the tool and as specified in the instructions supplied with the machine. 6.2.6.2 Attachment, workpiece and task The attachment or accessories to be used with the machine shall be as recommended in the user instruction. If these attachments are of a vibration reduction type, it shall be reported together with the declared vibration value. Care shall be taken that the location of the work piece on its support does not affect the results of the test. Details for task and work piece are given in the relevant Part 2. NOTE It should be noted that even small differences in size, shape, material, wear, unbalance, etc. of the accessory can alter the vibration magnitude considerably. 6.2.6.3 Operating conditions Tools are tested under load only, unless the operating condition no-load is considered as important in practical use (no-load accounts for more than 20 % of the time when tool is switched on). In this case the tool shall be tested under both load and no-load condition, or at a typical work cycle containing load and no-load. The relevant Part 2 describes the modes of operation and the calculation of the declared emission value. The machine shall be operated at normal working conditions and working modes according to the user instructions, which shall be maintained for the duration of the test. Those operating conditions shall be used that are representative of the highest vibration values likely to occur at typical and normal use of the machine under test. The measurement may be carried out by processing a work piece or under external mechanical load equivalent to normal operation. Before starting the test, the tool shall be operated under these conditions of at least 1 min to warm it up. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 6.2.6.4 Operator 6.2.7.1 Reported vibration value n a a s − − = ∑ hvi R ) ( n = i with n = 3 (number of operators) EN 60745-1:2006 The vibration of the machine is influenced by the operator. The operator shall therefore be skilled and able to operate the machine properly, i.e. he shall be experienced in the use of the tool. The gripping force shall be as under long term working conditions and not be excessive. 6.2.7 Measurement procedure and validity Three series of five consecutive tests shall be carried out using a different operator for each series. If it can be shown that the vibration is not affected by operator characteristics, it is acceptable to perform all 15 measurements with one operator only. Details are specified in the relevant Part 2. The measurements are made in three axes and the results of each direction shall be combined using equation (Z6) to obtain the vibration total value ahv. If the coefficient of variation CV of the five vibration total values ahv, recorded for each series, is less than 0,15 or the standard deviation sN–1 is less than 0,3 m/s², the results are accepted (Annex ZB provides information on possible sources of errors of measurement). The measurement result ah shall be determined as the arithmetic mean of vibration total values over the tests and operators. 6.2.7.2 Declaration of the vibration emission value The result ah is the basis for the declared value. If values have been obtained for different hand positions, the greatest value shall be the basis for the declaration. If required by the relevant Part 2, the work mode description corresponding to the vibration emission shall be stated next to each declared value. To determine the uncertainty K of the declared value according to EN 12096, the following formula shall be used that takes the standard deviation into account: K = 1,65 sR or K = 1,5 m/s² , whatever is higher h sR = standard deviation (considered equal to σR) ahvi = average vibration total value of each operator (= result for each operator) ah = average vibration total value of all measurements (= test result) Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI The vibration value(s) ah shall be declared as follows: Vibration total values (triax vector sum) determined according to EN 60745: Vibration emission value ah = ... m/s² Work mode description (if required by the relevant Part 2) Uncertainty K = … m/s² Vibration emission value ah = ... m/s² Work mode description (if required by the relevant Part 2) Uncertainty K = … m/s² 6.2.8 Measurement report The report shall, as a minimum, include the following information: a) reference to this standard including any relevant Part 2; b) specification of the machine tested (i.e. manufacturer, type and serial number of the machine, etc.); c) attachment or accessories; d) operating and testing conditions (voltage, feed force, speed setting, duration and number of test runs, etc.); e) measuring institution (e.g. laboratory, manufacturer); f) date of measurement and name of the person responsible for the test; g) instrumentation (transducer mass, filters, integrators, recording system, etc.); h) position and fastening of transducers, measuring directions and individual vibration values when relevant (e.g. recorded by photos); i) the arithmetic mean total vibration ah, for each operator the total vibration value ahv and the three single axis weighted acceleration values ahw. It is good practice to report all the measured values (i.e. for all axes of vibration, tests and operators); j) the uncertainty K of the vibration total value ah. Any deviations from the vibration test code in this standard shall be reported together with the technical justification for such deviations. Classification 7.1 Tools shall be of one of the following classes with respect to protection against electric shock: class I, class II, class III. Compliance is checked by inspection and by the relevant tests. 7.2 Tools shall have the appropriate degree of protection against harmful ingress of water according to IEC 60529. If a degree other than IPX0 is required this shall be specified in the relevant part 2. Compliance is checked by inspection and by the relevant tests. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Marking and instructions 8.1 Tools shall be marked with: – rated voltage(s) or rated voltage range(s), in volts. Tools for star-delta connection shall be clearly marked with the two rated voltages (for example 230 Δ/ 400 Y); – symbol for nature of supply, unless the rated frequency is marked. The symbol for nature of supply shall be placed next to the marking for rated voltage; – rated input, in watts or rated current, in amperes. The rated input or current to be marked on the tool is the total maximum input or current that can be on circuit at the same time. If a tool has alternative components which can be selected by a control device, the rated input or rated current is that corresponding to the highest loading possible; – name or trade mark or identification mark and address of the manufacturer or any other agent responsible for placing the tool on the market; – model or type reference; – symbol for class II construction, for class II tools only; – IP number according to degree of protection against ingress of water other than IPX0. If the first numeral for the IP numbering is omitted, the omitted numeral shall be replaced by the letter X, for example IPX5; – “WARNING – To reduce the risk of injury, user must read instruction manual” or the sign M002 of ISO 7010 F8). If used, the word “WARNING” shall be in capital letters not less than 2,4 mm high and shall not be separated from the cautionary statement. If used, the statement shall be verbatim except the term “operator’s manual” or “user guide” may be used for the term “instruction manual”; – the year of manufacture. Additional markings are allowed, provided they do not give rise to misunderstanding. Compliance is checked by inspection. 8.2 Tools for short-time operation or intermittent operation shall be marked with rated operating time, or rated operating time and rated resting time respectively, unless the operating time is limited by the construction of the tool. The marking of short-time operation or intermittent operation shall correspond to normal use. The marking of intermittent operation shall be such that the rated operating time precedes the rated resting time, both markings being separated by an oblique stroke. Compliance is checked by inspection. 8.3 The marking of tools intended to be operated without adjustment in a rated range of values (voltage, frequency, etc.) shall be differentiated from those intended to be operated with or without adjustment under different values of the same criteria (voltage, frequency, etc.). The lower and upper limits of the rated range of values shall be separated by a hyphen (-). The different rated values shall be separated by an oblique stroke (/). Examples: _________ 8) The future safety sign M002 is currently in DIS stage as ISO 7010:2003/DAmd4. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 115-230 V: The tool is suitable for any value within the marked range. 115/230 V: The tool is only suitable for the marked values. Compliance is checked by inspection. 8.4 If the tool can be adjusted to suit different rated voltages, the voltage to which the tool is adjusted shall be clearly discernible. This requirement does not apply to tools for star-delta connection. For tools where frequent changes in voltage setting are not required, this requirement is considered to be met if the rated voltage to which the tool is adjusted can be determined from a wiring diagram fixed to the tool. The wiring diagram may be on the inside of a cover which has to be removed to connect the supply conductors. It is not to be on a label loosely attached to the tool. Compliance is checked by inspection. 8.5 For tools marked with more than one rated voltage or with more than one rated voltage range, the rated power input for each of these voltages or ranges shall be marked. The upper and lower limits of the rated power input shall be marked on the tool so that the relation between input and voltage appears distinctly, unless the difference between the limits of a rated voltage range does not exceed 10 % of the mean value of the range, in which case the marking for rated power input may be related to the mean value of the range. Compliance is checked by inspection. 8.6 If units or technical data are expressed by symbols, the following symbols shall be used: V............................ volts A............................ amperes Hz.......................... hertz W........................... watts kW ......................... kilowatts F............................ farads μF.......................... microfarads l ............................. litres g............................ grams kg .......................... kilograms bar......................... bars Pa.......................... pascals h ............................ hours min ........................ minutes s ............................ seconds n0 .......................... no-load speed Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI .../min or …min–1 Revolutions or reciprocations per minute or d.c. Direct current or a.c. Alternating current Two-phase alternating current 2N Two-phase alternating current with neutral Three-phase alternating current 3N Three-phase alternating current with neutral A Rated current of the appropriate fuse-link in amperes Time-lag miniature fuse-link where X is the symbol for the time/current characteristic, as given in IEC 60127-3 x Protective earth Class II tool IPXX IP symbol The dimensions for the symbol for class II tools shall be such that the length of the sides of the outer square is about twice the length of the sides of the inner square. The length of the sides of the outer square shall not be less than 5 mm, unless the largest dimension of the tool does not exceed 15 cm, in which case the dimensions of the symbol may be reduced, but the length of the sides of the outer square shall not be less than 3 mm. The symbol for class II tools shall be so placed that it will be obvious that it is a part of the technical information, and is unlikely to be confused with any other marking. When other units are used, the units and their symbols shall be those of the international standardized system. Additional symbols other than international symbols are allowed, provided they do not give rise to misunderstanding. Compliance is checked by inspection and measurement. 8.7 Tools to be connected to more than two supply conductors shall be provided with a connection diagram, fixed to the tool, unless the correct mode of connection is obvious. The correct mode of connection is deemed to be obvious if the terminals for the supply conductors are indicated by arrows pointing towards the terminals. The earthing conductor is not a supply conductor. For tools for star-delta connection, the wiring diagram should show how the windings are to be connected. Compliance is checked by inspection. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 8.8 Except for type Z attachments, terminals shall be indicated as follows: – Terminals intended exclusively for the neutral conductor shall be indicated by the letter N. – Earthing terminals shall be indicated by the symbol These indications shall not be placed on screws, removable washers or other parts which might be removed when conductors are being connected. Compliance is checked by inspection. 8.9 Unless it is obviously unnecessary, switches which may give rise to a hazard when operated shall be marked, or so placed as to indicate clearly which part of the tool they control. Indications used for this purpose shall, wherever practicable, be comprehensible without a knowledge of languages, national standards, etc. Compliance is checked by inspection. 8.10 For tools which might cause danger when started unexpectedly, the “off” position of the mains switch shall be indicated, unless this position is obvious; the indication, if required, shall be the figure {, as given by symbol IEC 60417-5008 (DB:2002-10). The figure { shall not be used for any other indication. The position of the moving contacts of the mains switch shall correspond to the indications for the different positions of its operating means. NOTE The figure { may, for example, also be used on a digital programming keyboard. Compliance is checked by inspection. 8.11 Regulating devices and the like, intended to be adjusted during operation, shall be provided with an indication for the direction of adjustment to increase or to decrease the value of the characteristic being adjusted. An indication of + and – is considered to be sufficient. The requirement does not apply to regulating devices provided with an adjusting means, if its fully “on” position is opposite to its “off” position. If figures are used for indicating the different positions, the “off” position shall be indicated by the figure { and the other positions shall be indicated by figures reflecting the greater output, input, speed, etc. The indication for the different positions of the operating means of a control device need not to be placed on the device itself. Compliance is checked by inspection. 8.12 An instruction manual and safety instructions shall be provided with the tool and packaged in such a way that is noticed by the user when the tool is removed from the packaging. The safety instructions may be separate from the instruction manual. An explanation of the symbols required by this standard shall be provided in either the instruction manual or the safety instructions. They shall be written in the official language(s) of the country in which the tool is sold. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI They shall be legible and contrast with the background. They shall include the name and address of the manufacturer or supplier or any other agent responsible for placing the tool on the market. 8.12.1 The subjects of safety instructions are the General Power Tool Safety Warnings of Part 1 as given in 8.12.1.1, the specific tool Safety Warnings of the relevant part 2 and any additional safety warning statements deemed necessary by the manufacturer. The General Power Tool Safety Warnings and the specific tool Safety Warnings, if in English, shall be verbatim and in any other official language to be equivalent. Format of all Safety Warnings must differentiate, by font highlighting or similar means, the context of clauses as illustrated below. All notes in the safety instructions are not to be printed, they are information for the designer of the manual. 8.12.1.1 General Power Tool Safety Warnings WARNING Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. 1) Work area safety a) Keep work area clean and well lit. Cluttered or dark areas invite accidents. b) Do not operate power tools in explosive atmospheres, such as in the presence of flammable liquids, gases or dust. Power tools create sparks which may ignite the dust or fumes. c) Keep children and bystanders away while operating a power tool. Distractions can cause you to lose control. 2) Electrical safety a) Power tool plugs must match the outlet. Never modify the plug in any way. Do not use any adapter plugs with earthed (grounded) power tools. Unmodified plugs and matching outlets will reduce risk of electric shock. b) Avoid body contact with earthed or grounded surfaces, such as pipes, radiators, ranges and refrigerators. There is an increased risk of electric shock if your body is earthed or grounded. c) Do not expose power tools to rain or wet conditions. Water entering a power tool will increase the risk of electric shock. d) Do not abuse the cord. Never use the cord for carrying, pulling or unplugging the power tool. Keep cord away from heat, oil, sharp edges or moving parts. Damaged or entangled cords increase the risk of electric shock. e) When operating a power tool outdoors, use an extension cord suitable for outdoor use. Use of a cord suitable for outdoor use reduces the risk of electric shock. f) If operating a power tool in a damp location is unavoidable, use a residual current device (RCD) protected supply. Use of an RCD reduces the risk of electric shock. NOTE The term “residual current device (RCD)” may be replaced by the term “ground fault circuit interrupter (GFCI)” or “earth leakage circuit breaker (ELCB)”. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 3) Personal safety a) Stay alert, watch what you are doing and use common sense when operating a power tool. Do not use a power tool while you are tired or under the influence of drugs, alcohol or medication. A moment of inattention while operating power tools may result in serious personal injury. b) Use personal protective equipment. Always wear eye protection. Protective equipment such as dust mask, non-skid safety shoes, hard hat, or hearing protection used for appropriate conditions will reduce personal injuries. c) Prevent unintentional starting. Ensure the switch is in the off-position before connecting to power source and/or battery pack, picking up or carrying the tool. Carrying power tools with your finger on the switch or energising power tools that have the switch on invites accidents. d) Remove any adjusting key or wrench before turning the power tool on. A wrench or a key left attached to a rotating part of the power tool may result in personal injury. e) Do not overreach. Keep proper footing and balance at all times. This enables better control of the power tool in unexpected situations. f) Dress properly. Do not wear loose clothing or jewellery. Keep your hair, clothing and gloves away from moving parts. Loose clothes, jewellery or long hair can be caught in moving parts. g) If devices are provided for the connection of dust extraction and collection facilities, ensure these are connected and properly used. Use of dust collection can reduce dust-related hazards. 4) Power tool use and care a) Do not force the power tool. Use the correct power tool for your application. The correct power tool will do the job better and safer at the rate for which it was designed. b) Do not use the power tool if the switch does not turn it on and off. Any power tool that cannot be controlled with the switch is dangerous and must be repaired. c) Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments, changing accessories, or storing power tools. Such preventive safety measures reduce the risk of starting the power tool accidentally. d) Store idle power tools out of the reach of children and do not allow persons unfamiliar with the power tool or these instructions to operate the power tool. Power tools are dangerous in the hands of untrained users. e) Maintain power tools. Check for misalignment or binding of moving parts, breakage of parts and any other condition that may affect the power tool’s operation. If damaged, have the power tool repaired before use. Many accidents are caused by poorly maintained power tools. f) Keep cutting tools sharp and clean. Properly maintained cutting tools with sharp cutting edges are less likely to bind and are easier to control. g) Use the power tool, accessories and tool bits etc. in accordance with these instructions, taking into account the working conditions and the work to be performed. Use of the power tool for operations different from those intended could result in a hazardous situation. 5) Service a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. 8.12.1.2 The order of the Safety Instructions shall be either in accordance with either item A) or B) and in accordance with item C): Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI A) The Part 1 warnings are followed by the relevant part 2 warnings. The order of the warnings within the Part 1 and the part 2 warnings shall remain as given above and in the relevant part 2. numbered subtitles and the associated warnings below the numbered subtitle. The order of warnings within each section shall remain as given above and in the relevant part 2. When warnings are presented in this manner, the title of the Part 1 “General Power Tool Safety Warnings” shall be omitted and the 1st sentence of the warnings in 8.12.1.1 and 8.12.2, if applicable, shall be modified as follows: symbol and all instructions. The sections of the safety warnings shall be presented in the related topic of the Instruction Manual. The Instruction Manual section titles for Part 1 warnings shall have a format: General Power Tool Safety Warnings – [Section subtitle] Example: General Power Tool Safety Warnings – Personal Safety The Instruction Manual section titles for part 2 warnings shall have a format: [Tool category name] Safety Warnings – [Section subtitle] Example: Circular Saw Safety Warnings – Cutting Procedures If particular part 2 warnings do not have a numbered subtitle, then all warnings required by the particular part 2 shall be presented in the given order and the formatting rule above shall be followed without the [Section subtitle]. C) Any additional warnings deemed necessary by the manufacturer, shall not be inserted within any of the Part 1 or part 2 warnings. They may be either appended to the section(s) of the Part 1 or part 2 in accordance with the topic of the safety warnings or located in any other part of the instruction manual. 8.12.2 If the Safety Instructions are separate from the Instruction Manual, then the following warnings shall be included in the Instruction Manual. These warnings, if in English, shall be verbatim and in any other official language to be equivalent. WARNING Read all safety warnings and all instructions. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. The Instruction Manual shall be provided with the following information, if appropriate. a) Instructions for putting into use 1) Setting-up or fixing power tool in a stable position as appropriate for power tools which can be mounted on a support 2) Assembly 3) Connection to power supply, cabling, fusing, socket type and earthing requirements 4) Illustrated description of functions Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 5) Limitations on ambient conditions 6) List of contents b) Operating instructions 1) Setting and testing 2) Tool changing 3) Clamping of work 4) Limits on size of workpiece 5) General instructions for use c) Maintenance and servicing 1) Regular cleaning, maintenance, method for keeping tools sharp, and lubrication 2) Servicing by manufacturer or agent; list of addresses 3) List of user-replaceable parts 4) Special tools which may be required 5) For power tools with type X attachment, where a specially prepared cord is needed to replace the cord: if the supply cord of this power tool is damaged, it must be replaced by a specially prepared cord available through the service organization. 6) For power tools with type Y attachment: if the replacement of the supply cord is necessary, this has to be done by the manufacturer or his agent in order to avoid a safety hazard. 7) For power tools with type Z attachment: the supply cord of this power tool cannot be replaced, and the power tool shall be scrapped. d) For tools with a liquid system, the substance of the following, as appropriate: 1) Instructions for - the connection to the liquid supply; - the use of the liquid and the use of attachments to comply with 14.4 in order to avoid affection of the tool by liquid; - the inspection of hoses and other critical parts which could deteriorate; - the maximum permitted pressure of the liquid supply 2) For tools provided with an RCD - warning and instruction never to use the tool without the RCD provided with the tool; - warning and instruction always to test the correct operation of the RCD before starting work, unless the RCD is of a self-checking type 3) For tools for use in combination with an isolating transformer: warning and instruction never to use the tool without the transformer delivered with the tool or of the type as specified in these instructions 4) Warning and instruction that replacement of the plug or the supply cord shall always be carried out by the manufacturer of the tool or his service organization 5) Warning and instruction to keep liquid clear off the parts of the tool and away from persons in the working area Za) Emissions 1) The noise emission measured in accordance with 6.1.2. 2) Recommendation for the operator to wear hearing protection. 3) The vibration emission measured in accordance with 6.2. When the vibration emission value does not exceed 2,5 m/s², this shall be stated. When the vibration emission exceeds 2,5 m/s², its value shall be given in the instructions. 8.13 Markings required by the standard shall be easily legible and durable. Signs shall be in contrast such as colour, texture, or relief, to their background such that the information or Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI instructions provided by the signs are clearly legible when viewed by the naked eye from a distance of not less than 500 mm. Signs need not be in accordance with the blue colour requirements of ISO 3864-2. Compliance is checked by inspection and by rubbing the marking by hand for 15 s with a piece of cloth soaked with water and again for 15 s with a piece of cloth soaked with petroleum spirit. After all the tests of this standard, the marking shall be easily legible, it shall not be easily possible to remove marking plates, and they shall show no curling. In considering the durability of the marking, the effect of normal use is taken into account. Thus, for example, marking by means of paint or enamel other than vitreous enamel on containers that are likely to be cleaned frequently is not considered to be durable. The petroleum spirit to be used for the test is aliphatic solvent hexane having a maximum aromatics content of 0,1 % by volume, a kauributanol value of 29, an initial boiling point of approximately 65 °C, a dry point of approximately 69 °C and a specific mass of approximately 0,689 kg/l. 8.14 Markings specified in 8.1 to 8.5 shall be on a main part of the tool. Markings specified in 8.1, 8.2, 8.3 and 8.5 shall be placed together. Markings on the tool shall be clearly discernible from the outside of the tool, but after removal of a cover, if necessary. It shall be possible to remove or open this cover without the aid of a tool. Indications for switches and controls shall be placed on or in the vicinity of these components; they shall not be placed on parts which can be repositioned, or positioned in such a way that the marking is misleading. Compliance is checked by inspection. 8.15 If compliance with this standard depends upon the operation of a replaceable thermal link or fuse-link, the reference number or other means for identifying the link shall be marked on the link, or in a place that it is clearly visible after the link has failed, when the tool has been dismantled to the extent necessary for replacing the link. This requirement does not apply to links which can only be replaced together with a part of the tool. Compliance is checked by inspection. Protection against access to live parts Tools shall be so constructed and enclosed that there is adequate protection against accidental contact with live parts. Compliance is checked by inspection, and by the tests of 9.2 to 9.4, as applicable. 9.1 An accessible part is not considered to be live if: – the part is supplied with safety extra-low voltage, provided that • for a.c., the peak value of the voltage does not exceed 42 V; • for d.c., the voltage does not exceed 42 V; Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI or – the part is separated from live parts by protective impedance. In the case of protective impedance, the current between the part and the supply source shall not exceed 2 mA for d.c., and its peak value shall not exceed 0,7 mA for a.c., and moreover: – for voltages having a peak value over 42 V up to and including 450 V, the capacitance shall not exceed 0,1 μF; – for voltages having a peak value over 450 V up to and including 15 kV, the discharge shall not exceed 45 μC. Compliance is checked by operating the tool at rated voltage. Voltages and currents are measured between the relevant parts and either pole of the supply source. Discharges are measured immediately after the interruption of the supply. 9.2 The requirement of 9.1 applies for all positions of the tool when it is operated as in normal use, even after removal of detachable parts. Lamps located behind a detachable cover are not removed, provided the tool can be isolated from the supply by means of a plug or an all-pole switch. However, during insertion or removal of lamps which are located behind a detachable cover, protection against contact with live parts of the lamp cap shall be ensured. This excludes the use of screw type fuses and screw-type miniature circuit breakers which are accessible without the aid of a tool. The test finger of Figure 1 is applied without appreciable force, the tool being in every possible position. Through openings, the test finger is applied to any depth that the finger will permit, and it is rotated or angled before, during, and after insertion to any position. If the opening does not allow the entry of the finger, the force on the finger in the straight position is increased to 20 N and the test with the finger bent repeated. It shall not be possible to touch with the test finger live parts or live parts protected only by lacquer, enamel, ordinary paper, cotton, oxide film, beads or sealing compound. Lacquer, enamel, ordinary paper, cotton, oxide film on metal parts, beads and sealing compound, except self-hardening resins, are not considered to give the required protection against contact with live parts. 9.3 For openings in class II tools or class II constructions, except for those giving access to lamp caps or live parts in socket-outlets of class I tools, the test pin of Figure 2 is applied without appreciable force. It shall not be possible to touch live parts with the test pin. 9.4 In addition, class II tools and class II constructions shall be so constructed and enclosed that there is adequate protection against accidental contact with basic insulation, and metal parts separated from live parts by basic insulation only. Parts which are not separated from live parts by double insulation or reinforced insulation shall not be accessible. Compliance is checked by inspection and by applying the test finger of Figure 1. This requirement applies for all positions of the tool when it is operated as in normal use, even after removal of detachable parts. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 10 Starting 10.1 Motors shall start under all normal voltage conditions which may occur in use. Compliance is checked by operating the tool with no-load 10 times at a voltage equal to 0,85 times rated voltage, regulating devices, if any, being set as in normal use. In all cases, the tool shall function safely and correctly. 10.2 Centrifugal and other automatic starting switches shall operate reliably, and without contact chattering. Tools provided with a centrifugal or other automatic starting switch are, in addition, operated 10 times at a voltage equal to 1,1 times rated voltage. The interval between consecutive starts is made sufficiently long to prevent undue heating. In all cases, the tool shall function safely and correctly. 10.3 Overload protection devices shall not operate under normal starting conditions. The tests of 10.1 and 10.2 check compliance with this requirement. 11 Input and current The rated power input or rated current shall be at least 110 % of the measured no-load input or current. For tools marked with one or more rated voltage ranges, the test is made at both the upper and lower limits of the ranges, unless the marking or the rated power input is related to the mean value of the relevant voltage range, in which case the test is made at a voltage equal to the mean value of that range. Compliance is checked by measuring the power input or current of the tool when stabilized while all circuits which can operate simultaneously are in operation. 12 Heating 12.1 Tools shall not attain excessive temperatures under normal load. Compliance is checked by determining the temperature rise of the various parts under the conditions specified in 12.2 to 12.5 immediately followed by the test of Clause 13 with the tool in the “on” position and under the following conditions. For single-phase tools and for three-phase tools suitable for single-phase supply: S1 of Figure 3 in the “on” position, for three-phase tools with the three sections connected in parallel. For three-phase tools not suitable for single-phase supply: a, b and c in Figure 4 in the ″on″ position, repeated with each of the switches a, b, c open in turn, the other two switches being closed. For heating elements, the measurements are repeated with each of the switches a, b and c open in turn, the other two switches being closed. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 12.2 The tool is operated in still air under normal load. While the torque is maintained, the voltage is then adjusted to 0,94 times the rated voltage or 1,06 times the rated voltage, or the mean of the rated voltage range, whichever is the most unfavourable. Heating elements, if any, are operated under the conditions specified in Clause 11 of IEC 60335-1, when the tool is operated at a voltage equal to 1,06 times rated voltage. 12.3 Temperature rises, other than those of windings, are determined by means of fine-wire thermocouples so chosen and positioned that they have the minimum effect on the temperature of the part under test. The temperature rise of electrical insulation, other than that of windings, is determined on the surface of insulation, at places where failure could cause a short circuit, contact between live parts and accessible metal parts, bridging of insulation, or reduction of creepage distances or clearances below the values specified in 28.1. Temperature rises of windings are determined by the resistance method, unless the windings are non-uniform, or the method involves severe complications to make the necessary connections for the resistance measurement. In that case, the measurement is made by thermocouples. Such temperature rises are determined by means of fine-wire thermocouples so chosen and positioned that they have the minimum effect on the temperature of the part under test. In determining the temperature rises of handles, knobs, grips and the like, consideration is given to all parts which are gripped in normal use, and, if of insulating material, to those parts in contact with hot metal. NOTE 1 If it is necessary to dismantle the tool to position thermocouples, the power input is measured again to check that the tool has been correctly reassembled. NOTE 2 The point of separation of the cores of a multicore cord is an example of a place where thermocouples are positioned. 12.4 The tool is operated: – for the rated operating time for tools for short time operation; – on consecutive cycles of operation, until steady conditions are established, for tools for intermittent operation, the "on" and "off" periods being the rated "on" and "off" periods; – until steady conditions are established for tools for continuous operation. 12.5 During the test, protective devices shall not operate. The temperature rises shall not exceed the values shown in Table 1, except as allowed by 12.6. Sealing compound, if any, shall not flow out. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Windings a), if the winding insulation according to IEC 60085 is: − class 105 − class 120 − class 130 − class 155 − class 180 − class 200 − class 220 − class 250 Pins of appliance inlets: − for hot conditions − for cold conditions Ambient of switches, temperature limiters b): − without T-marking − with T-marking Rubber or polyvinyl chloride insulation of internal and external wiring, including supply cords: – without temperature rating c) – with temperature rating (T) Rubber, other than synthetic, used for gaskets or other parts, the deterioration of which could affect safety: – when used as supplementary insulation or as reinforced insulation – in other cases Lampholders E14 and B15: – metal or ceramic type – insulated type, other than ceramic – with T-marking Material used as insulation other than that specified for wires and windings d) – impregnated or varnished textile, paper or press board – laminates bonded with: • melamine-formaldehyde; phenol-formaldehyde or phenol-furfural resins • urea-formaldehyde resin – printed circuit boards bonded with epoxy resin – moulding of: • phenol-formaldehyde with cellulose fillers • phenol-formaldehyde with mineral fillers • melamine-formaldehyde • urea-formaldehyde – polyester with glass-fibre reinforcement – silicone rubber – polytetrafluoroethylene – pure mica and tightly sintered ceramic material when such materials are used as supplementary insulation or reinforced insulation – thermoplastic material e) EN 60745-1:2006 Table 1 – Maximum normal temperature rises Parts Temperature rise K (65) (80) (85) T-25 T-25 Cord sheath used as supplementary insulation T-25 (175) (150) (175) (200) (175) (150) − Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Outer surface of capacitors g): – without marking of maximum operating temperature: • small ceramic capacitors for radio and television interference suppression • capacitors complying with IEC 60384-14 or 14.2 of IEC 60065 • other capacitors g) External enclosure of tools without heating elements except handles held in normal use – of metal – of porcelain or vitreous material – of moulded material, rubber or wood – of metal – of porcelain or vitreous material – of moulded material, rubber or wood EN 60745-1:2006 Table 1 (continued) Wood, in general f) T-25 – with marking of maximum operating temperature (T) Handles, knobs, grips and the like which, in normal use, are continuously held: Handles, knobs, grips and the like which, in normal use, are held for short periods only (e.g. switches): Parts in contact with oil having a flash-point of t °C t-50 a) To allow for the fact that the average temperature of windings of universal motors, relays, solenoids, etc., is usually above the temperature at the points on the windings where thermocouples are placed, the figures without parentheses apply when the resistance method is used, and those within parentheses apply when thermocouples are used. For windings of vibrator coils and a.c. motors, the figures without parentheses apply in both cases. For motors constructed so that the circulation of the air between the inside and the outside of the case is prevented, but not necessarily sufficiently enclosed to be called airtight, the temperature rise limits may be increased by 5 K. b) T signifies the maximum operating temperature. The ambient temperature of switches, thermostats and temperature limiters is the temperature of the air at the hottest point at a distance of 5 mm from the surface of the switch and component concerned. For the purpose of this test, switches and thermostats marked with individual ratings may be considered as having no marking for the maximum operating temperature, if requested by the tool manufacturer. c) This limit applies to cables, cords and wires complying with the relevant IEC standards; for others, it may be different. d) The values in parentheses apply, if the material is used for handles, knobs, grips and the like, and is in contact with hot metal. e) There is no specific limit for thermoplastic material, which has to withstand the tests of 29.1, for which purpose the temperature rise must be determined. f) The limit specified concerns the deterioration of wood, and it does not take into account deterioration of surface finishes. g) There is no limit for the temperature rise of capacitors which are short-circuited in 18.10. If these or other materials are used, they shall not be subjected to temperatures in excess of the thermal capabilities as determined by ageing tests made on the materials themselves. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Table 1 (continued) The value of the temperature rise of a winding is calculated from the formula: R2 – R1 Δt = _________ (k + t1 ) – (t2 – t1 ) R1 where Δt is the temperature rise; R1 is the resistance at the beginning of the test; R2 is the resistance at the end of the test; k is equal to 234,5 for copper windings, and 225 for aluminium windings; t1 is the ambient temperature at the beginning of the test; t2 is the ambient temperature at the end of the test. At the beginning of the test, the windings are to be at ambient temperature. It is recommended that the resistance of windings at the end of the test be determined by taking resistance measurements as soon as possible after switching off, and then at short intervals so that a curve of resistance against time can be plotted for ascertaining the resistance at the instant of switching off. 12.6 If the windings are classified according to IEC 60085 and the temperature rise does not exceed the value in Table 1, the following test is not necessary. Three additional samples are subjected to the following tests. a) The samples are dismantled as far as is possible without damaging any part. Windings are kept for 10 days (240 h) in a heating cabinet, the temperature of which is (80 ± 1) °C in excess of the temperature rise of the windings determined according to 12.3. b) After this treatment, the samples are reassembled and no interturn short circuit shall occur. Interturn short circuits may be detected by means of a winding tester. c) The samples are then subjected to a humidity treatment as specified in 14.3. d) After this treatment, they shall withstand the tests of Clauses 13 and 15. Faults which may occur in insulation, which did not show an excessive temperature rise during the test of 12.3, are ignored and are repaired, if necessary, in order to complete the tests of this subclause. 13 Leakage current 13.1 The leakage current shall not be excessive. Compliance is checked by the following test at a supply voltage equal to 1,06 times rated voltage. The leakage current test is made with a.c. unless the tool is for d.c. only, in which case the test is not made. Protective impedance is disconnected from live parts before carrying out the tests. It is recommended that the tool be supplied through an isolating transformer; otherwise, it must be insulated from earth. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 13.2 The leakage current is measured by means of the circuit of Figure 10 between any pole of the supply and accessible metal parts and metal foil with an area not exceeding 20 cm × 10 cm in contact with accessible surfaces of insulating material, connected together. The metal foil has the largest area possible on the surface under test, without exceeding the dimensions specified. If its area is smaller than the surface under test, it is moved so as to test all parts of the surface. The heat dissipation of the tool shall, however, not be affected by the metal foil. Three-phase tools, which are suitable for single-phase supply, are tested as single-phase tools with the three sections connected in parallel. For single-phase tools and three-phase tools to be tested as single-phase tools, the leakage current is measured with the selector switch shown in Figure 3, in each of the positions 1 and 2, and the switch S1 in “on” position. For three-phase tools not suitable for single-phase supply, the leakage current is measured according to Figure 4, with the switches a, b and c in the “on” position. For tools intended to be connected in star connection only, the neutral is not connected. The leakage current is measured within 5 s after the application of the test voltage and shall not exceed the following values: – to accessible metal parts and metal foil: • for class I tools 0,75 mA; • for class II tools 0,25 mA; • for class III tools 0,5 mA. If the tool incorporates one or more capacitors, and is provided with a single-pole switch, the measurements are repeated with the switch in the “off” position. 14 Moisture resistance 14.1 The enclosure of the tool shall provide the degree of protection against moisture in accordance with the classification of the tool. Compliance is checked by the appropriate treatment specified in 14.1.2, with the tool conditions as in 14.1.1. 14.1.1 The tool is not connected to the supply. Tools are turned continuously through the most unfavourable positions during the test. Tools with type X attachment are fitted with the lightest permissible type of flexible cord of the smallest cross-sectional area specified in 25.2; other tools are tested as delivered. Electrical components, covers and other parts which can be removed without the aid of a tool are removed and subjected, if necessary, to the relevant treatment with the main part. 14.1.2 Tools other than IPX0 are subjected to tests of IEC 60529 as follows: – IPX1 tools are subjected to the test described in 14.2.1; – IPX2 tools are subjected to the test described in 14.2.2; – IPX3 tools are subjected to the test described in 14.2.3; – IPX4 tools are subjected to the test described in 14.2.4; Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI – IPX5 tools are subjected to the test described in 14.2.5; – IPX6 tools are subjected to the test described in 14.2.6; – IPX7 tools are subjected to the test described in 14.2.7. For this last test, the tool is immersed in water containing approximately 1,0 % NaCl. Immediately after the appropriate treatment, the tool shall withstand the electric strength test of Clause 15, and inspection shall show that there is no trace of water on insulation which could result in a reduction of creepage distances and clearances below the values specified in 28.1. Tools which are not subject to spillage of liquid in normal use are allowed to stand in normal test-room atmosphere for 24 h before being subjected to the test of 14.3. 14.2 Tools subject to spillage of liquid in normal use shall be so constructed that such spillage does not affect their electrical insulation. Compliance is checked by the following test: Tools incorporating an appliance inlet are fitted with an appropriate connector and flexible cord; tools with type X attachment are fitted with the lightest permissible type of flexible cord of the smallest cross-sectional area specified in 25.2; other tools are tested as delivered. Electrical components, covers and other parts which can be removed without the aid of a tool are removed, except those fulfilling the test of 21.22. The liquid container of the tool is completely filled with water containing approximately 1,0 % NaCl, and a further quantity, equal to 15 % of the capacity of the container, or 0,25 l, whichever is the greater, is poured in steadily over a period of 1 min. Immediately after this treatment, the tool shall withstand an electric strength test as specified in Clause 15, and inspection shall show that there is no trace of water on insulation which could result in a reduction of creepage distances and clearances below the values specified in 28.1. The tool is allowed to stand in normal test-room atmosphere for 24 h before being subjected to the test of 14.3. 14.3 Tools shall be proof against humid conditions which may occur in normal use. Compliance is checked by the following humidity test. Cable entries, if any, are left open; if knock-outs are provided, one of them is opened. Electrical components, covers, and other parts which can be removed without the aid of a tool are removed and subjected, if necessary, to the humidity test with the main part. The humidity treatment is carried out in a humidity cabinet containing air with a relative humidity of (93 ± 2) %, obtained e.g. by placing in the humidity cabinet a saturated solution of Na2SO4 or KNO3 in water, having a sufficiently large contact surface with the air. The temperature of the air, at all places where samples can be located, is maintained within 1 K of any convenient value t between 20 °C and 30 °C. In order to achieve the specified conditions within the cabinet, it is necessary to ensure constant circulation of the air within and, in general, to use a cabinet which is thermally insulated. Before being placed in the humidity cabinet, the sample is brought to a temperature between it at this temperature for at least 4 h before the humidity treatment. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI The tool is kept in the cabinet for 48 h. Immediately after this test, the tool shall withstand the tests of Clause 13 at rated voltage or the mean of the rated voltage range with the tool switch in the “on” position and under the following conditions. For single-phase tools and for three-phase tools to be tested as single-phase tools: S1 of Figure 3 in the “off” position. For three-phase tools not suitable for single-phase supply: a in Figure 4 in the “on” position, b and c in “off” position. Then the tool shall withstand the test of Clause 15 in the humidity cabinet, or in the room in which the tool was brought to the prescribed temperature after reassembly of those parts which may have been removed. 14.4 Liquid systems shall not subject the user to an increased risk of electrical shock during foreseeable misuse. Compliance is checked by the following test: The residual current device, if any, shall be disabled during the test. The tool is operated at rated voltage with approximately 1,0 % NaCl solution in the following modes if applicable: • after overfilling of the fluid reservoir by 15 % of the capacity of the container, or by 0,25 l, whichever is the greater; • omission of a washer or other user removable part; • mis-assembly of liquid system connections routinely made by the user. In each mode, the tool is operated for 1 min in all positions consistent with the relevant part 2 and the manufacturer's instructions while monitoring the leakage current as in Clause 13. During the test the leakage current shall not exceed: • 2 mA for a class II tool; • 5 mA for a class I tool. Following this test, the tool shall meet the test of 13.1 after being allowed to dry for 24 h at ambient temperature. 14.5 Liquid systems shall be constructed of components capable of withstanding the pressure in normal use without leaking. Compliance is checked by the following test: The liquid system is closed and an approximately 1,0 % NaCl solution at a hydrostatic pressure equal to twice the pressure stated in 8.12.2 d) 1) is applied for 1 h. The leakage current of accessible parts is measured as described in Clause 13. During the test the leakage current shall not exceed: • 2 mA for a class II tool; • 5 mA for a class I tool. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Following this test, the tool shall meet the test of 13.1 after being allowed to dry for 24 h at ambient temperature. The residual current device, if any, shall be disabled during the test. 14.6 Residual current devices used to provide protection from shock in the case of failure of the liquid system shall comply with IEC 61540 and shall meet the following requirements a) to c): a) The RCD shall disconnect both mains conductors, but not the earth conductor if provided, when the leakage exceeds 10 mA and with a maximum response of 300 ms. Compliance is checked by inspection and the test of 9.9.2 of IEC 61540. In addition, during the test, the earthing conductor shall not become disconnected. b) The RCD shall be reliable for its intended use. Compliance is checked at rated voltage by operating the residual current device under conditions of simulated leakage as in (a) above during conditions of locked rotor of the tool for 50 cycles. The residual current device shall operate correctly for all cycles. c) The RCD shall be installed such that it is unlikely to be removed during use or routine normal maintenance. This requirement is considered fulfilled if the residual current device is fixed to the tool or the power supply cord connected to the tool. Where fitted in the supply cord, the residual current device shall be provided with Type Y attachment or Type Z attachment for connection with the supply cord and interconnecting cord. Compliance is checked by inspection. 15 Electric strength 15.1 The electric strength shall be adequate. Compliance is checked by the tests of 15.2. Protective impedance is disconnected from live parts before carrying out the tests. The tests are made on the tools at room temperature and not connected to the supply. 15.2 The insulation is subjected for 1 min to a voltage of substantially sinusoidal waveform, having a frequency of 50 Hz or 60 Hz. The value of the test voltage and the points of application are shown in Table 2, unless otherwise specified. Accessible parts of insulated material are covered with metal foil. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Table 2 – Test voltages 1. Between live parts and accessible parts separated from live parts by – basic insulation only – reinforced insulation 2. For parts with double insulation, between metal parts separated from live parts by basic insulation only, and – live parts – accessible parts 3. Between metal enclosures or covers lined with insulating material and metal foil in contact with the inner surface of the lining, if the distance between live parts and these metal enclosures or covers, measured through the lining, is less than the appropriate clearance as specified in 28.1 4. Between metal foil in contact with handles, knobs, grips and the like and their shafts, if these shafts can become live in the event of an insulation fault 5. Between accessible parts and internal diameter of cord guard wrapped with metal foil 6. Between the point where a winding and a capacitor are connected together, if a resonance voltage U occurs between this point and any terminal for external conductors, and – accessible parts a) – insulation only No flashover or breakdown shall occur during the test. EN 60745-1:2006 Test voltage V Points of application Class III tools Class II tools and construction and construction Other tools − 1 250 − 3 750 3 750 − 1 250 1 250 2 500 2 500 − − 2 500 1 250 2 500 − 2 500 − 2 500 1 250 − − 2 U + 1 000 − − 2 U + 1 000 a) The test between the point where a winding and a capacitor are connected together, and accessible parts or metal parts, is only made where the insulation is subjected to the resonance voltage under normal running conditions. Other parts are disconnected, and the capacitor is short-circuited. Initially, not more than half the prescribed voltage is applied, then it is raised rapidly to the full value. The high-voltage transformer used for the test must be so designed that, when the output terminals are short-circuited after the output voltage has been adjusted to the appropriate test voltage, the output current is at least 200 mA. The overcurrent relay must not trip when the output current is less than 100 mA. Care is taken that the r.m.s. value of the test voltage applied is measured within ±3 %. Care is taken that the metal foil is so placed that no flashover occurs at its edges or the edges of the insulation. For class II construction incorporating both reinforced insulation and double insulation, care is taken that the voltage applied to the reinforced insulation does not overstress the basic insulation, or the supplementary insulation. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI In cases where basic insulation and supplementary insulation cannot be tested separately, the insulation provided is subjected to the test voltages specified for reinforced insulation. When testing insulating coatings, the metal foil may be pressed against the insulation by means of a sandbag of such a size that the pressure is about 5 kPa (0,5 N/cm2). The test may be limited to places where the insulation is likely to be weak, for example where there are sharp metal edges under the insulation. If practicable, insulating linings are tested separately. For tools with heating elements incorporated, the test voltages specified in IEC 60335-1 apply to the heating elements only and not to other parts of the tool. 16 Overload protection of transformers and associated circuits Tools incorporating circuits supplied from a transformer shall be so constructed that, in the event of short circuits which are likely to occur in normal use, excessive temperatures do not occur in the transformer, or in the circuits associated to the transformer. Examples of short-circuits which are likely to occur in normal use are the short-circuiting of bare or inadequately insulated conductors of safety extra-low voltage circuits which are accessible, and the internal short-circuiting of lamp filaments. A failure of insulation complying with the requirements specified for basic insulation of class I or class II construction is not, for the purpose of this requirement, considered as likely to occur in normal use. Compliance is checked by applying the most unfavourable short circuit or overload which is likely to occur in normal use, the tool being operated at a voltage equal to 1,06 times, or 0,94 times, rated voltage, whichever is the more unfavourable. The temperature rise of the insulation of the conductors of safety extra-low voltage circuits is determined, and shall not exceed the relevant value specified in Table 1 by more than 15 K. The winding temperature of transformers shall not exceed the value specified for windings in 18.9, except for transformers which comply with IEC 61558-1. NOTE Protection of transformer windings may be, for example, obtained by the inherent impedance of the winding, or by means of fuses, automatic switches, thermal cut-outs or similar devices incorporated in the transformer, or similar devices located inside the tool only accessible with the aid of a tool. 17 Endurance 17.1 Tools shall be so constructed that, in extended normal use, there will be no electrical or mechanical failure that might impair compliance with this standard. The insulation shall not be damaged and contacts and connections shall not work loose as a result of heating, vibrations, etc. Moreover, overload protection devices shall not operate under normal running conditions. Compliance is checked by the test of 17.2 and, for tools provided with a centrifugal or other starting switch, also by the test of 17.3. Immediately after these tests, the tool shall withstand an electric strength test as specified in Clause 15, the test voltages being, however, reduced to 75 % of the specified values. Connections shall not have worked loose, and there shall be no deterioration impairing safety in normal use. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 17.2 The tool is operated intermittently with no-load for 24 h of operation at a voltage equal to 1,1 times rated voltage, and then for 24 h at a supply voltage equal to 0,9 times rated voltage. The tool may be switched on and off by means of a switch other than that incorporated in the tool. Each cycle of operation comprises an "on" period of 100 s and an "off" period of 20 s, the "off" periods being included in the specified operating time. The operating period for tools for short-time or intermittent operation is equal to the operating time, if this is limited by the construction of the tool; otherwise, it is in accordance with the prescriptions given in part 2, or with the marking, whichever is the more unfavourable. During the test, the tool is placed in three different positions, the operating time, at each test voltage, being approximately 8 h for each position. During this test, replacement of the carbon brushes is allowed, and the tool is oiled and greased as in normal use. If the temperature rise of any part of the tool exceeds the temperature rise determined during the test of 12.1, forced cooling or rest periods are applied, the rest periods being excluded from the specified operating time. During these tests, overload protection devices shall not operate. NOTE The change of position is made to prevent abnormal accumulation of carbon dust in any particular place. Examples of the three positions are horizontal, vertically up and vertically down. 17.3 Tools provided with a centrifugal or other automatic starting switch are started 10 000 times under normal load, and at a voltage equal to 0,9 times rated voltage, the operating cycle being that specified in 17.2. 18 Abnormal operation 18.1 Tools shall be so designed that the risk of fire and mechanical damage impairing safety or the protection against electric shock as a result of abnormal operation is obviated as far as is practicable. Fuses, thermal cut-outs, overcurrent protection devices or the like, incorporated into the tool, may be used to provide the necessary protection. Compliance is checked by the tests of 18.2 to 18.9. 18.2 Tools incorporating heating elements are subjected to the tests of 18.3 and 18.4. Moreover, tools provided with a control limiting the temperature during Clause 12 tests unless specifically excluded by part 2, are subjected to the tests of 18.5, and where applicable, to the test of 18.6. Only one abnormal condition is simulated each time. If more than one of the tests are applicable to the same tool, these tests are made consecutively. Unless otherwise specified, the tests are continued until a non-self-resetting thermal cut-out operates, or until steady conditions are established. If, during the test, a heating element or an intentionally weak part is permanently open-circuited, the relevant test is repeated on a second sample. This second test shall be terminated in the same way, unless the test is otherwise satisfactorily completed. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI An intentionally weak part is a part intended to fail under conditions of abnormal operation so as to prevent the occurrence of a condition which could impair compliance with this standard. Such a part may be a replaceable component, such as a resistor, a capacitor, or a thermal link, or a part of a component to be replaced, such as an inaccessible and non-resettable thermal cut-out incorporated in a motor. 18.3 Tools with heating elements are tested under the conditions specified in Clause 12, but with restricted heat dissipation. The supply voltage, determined prior to the test, is that required to provide a power input of 0,85 times the rated power input under normal operation, when steady conditions have been established. This voltage is maintained throughout the test. The tool is allowed to cool down to approximately room temperature before being subjected to the test of 18.4. 18.4 The test of 18.3 is repeated, but with a supply voltage, determined prior to the test, equal to that required to provide a power input of 1,24 times rated power input under normal operation, when steady conditions have been established. This voltage is maintained throughout the test. 18.5 The tool is tested under the conditions specified in Clause 12, under normal operation, the supply voltage being such that the power input is 1,15 times rated power input, but with any control which limits the temperature during the test of Clause 12 short-circuited. If the tool is provided with more than one control, these are short-circuited in turn. 18.6 Unless an all-pole disconnection occurs during the test of 18.5 for class I tools with tubular sheathed and embedded heating elements, but which are not intended to be permanently connected to fixed wiring, the test of 18.5 is repeated, with the controls which limit the temperature during the test of Clause 12 not short-circuited, and one end of the element connected to earth. This test is repeated with the polarity of the supply to the tool reversed and with the other end of the element connected to earth. 18.7 The following test is performed with cutting tools, such as sawblades, grinding wheels, etc., removed. – Tools incorporating a commutator motor are operated at a voltage equal to 1,3 times rated voltage, or the upper limit of the voltage range, for 1 min at no-load. After the tests of 18.2 to 18.7, the safety of the tool shall not have been impaired, in particular windings and connections shall not have worked loose. After these tests, the tool need not be capable of further use. 18.8 The following categories of tools incorporating induction motors and: a) with a starting torque less than the full-load torque; or b) started by hand; or c) provided with moving parts which are liable to be jammed, or where the moving parts can be stopped by hand, the motor remaining switched on during this operation; are connected, starting from cold, to their rated voltage or the upper limit of their rated voltage range with the moving parts locked • for 30 s for tools that are operated by hand during use; • for 5 min for tools that are attended during use. At the end of the test period specified, or at the instant of operation of fuses, thermal cut- outs, motor protection devices, and the like, the temperature of the windings shall not exceed the values shown in Table 3. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 18.9 Tools incorporating three-phase motors are operated, starting from cold, • for 30 s, if they are kept switched on by hand or continuously loaded by hand; • or otherwise, for 5 min, with one phase disconnected, and under the torque producing normal load. At the end of the test period specified, or at the instant of operation of fuses, thermal cut- outs, motor protection devices, and the like, the temperature of the windings shall not exceed the values shown in Table 3. Table 3 – Maximum winding temperature Limiting temperature °C Class Protection of windings Protection by inherent impedance Protection by protective devices which operate during the test 18.10 Electronic circuits shall be so designed and applied so that a fault condition will not render the tool unsafe with regard to electric shock, fire hazard, mechanical hazard or dangerous malfunction. Compliance is checked by evaluation of the fault conditions specified in 18.10.2 for all circuits or parts of circuits, unless they comply with the conditions specified in 18.10.1. If the safety of the tool under any of the fault conditions depends on the operation of a miniature fuse-link complying with IEC 60127-3, the test of 18.10.3 is made. If a conductor of a printed circuit board becomes open-circuited, the tool is considered to have withstood the particular test, provided all three of the following conditions are met: – the base material of the printed circuit board withstands the test of Annex F; – any loosened conductor does not reduce the creepage distances or clearances between live parts and accessible metal parts below the values specified in Clause 28; – the tool withstands the tests of 18.10.2 with the open-circuited conductor bridged. NOTE Examination of the tool and its circuit diagram will reveal the fault conditions which have to be simulated, so that testing can be limited to those cases which may be expected to give the most unfavourable result. 18.10.1 Fault conditions a) to f) specified in 18.10.2 are not applied to circuits or parts of circuits when both of the following conditions are met: – the electronic circuit is a low-power circuit as described below; – the protection against electric shock, fire hazard, mechanical hazard or dangerous malfunction of other parts of the tool does not rely on the correct functioning of the electronic circuit. An example of a low-power circuit is shown in Figure 11 and is determined as follows. The tool is operated at rated voltage or at the upper limit of the rated voltage range and a variable resistor, adjusted to its maximum resistance, is connected between the point to be investigated and the opposite pole of the supply source. The resistance is then decreased until the power consumed by the resistor reaches a maximum. Any point closest to the supply at which the maximum power delivered to this resistor does not exceed 15 W at the end of 5 s is called a low power point. The part of the circuit farther from the supply source than a low power point is considered to be a low-power circuit. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI The measurements are made from only one pole of the supply source, preferably the one that gives the fewest low power points. NOTE When determining the low power points, it is recommended to start with the points close to the supply source. 18.10.2 The following fault conditions are considered and, if necessary, applied one at a time, consequential faults being taken into consideration: a) short-circuit of creepage distances and clearances between conductive parts of different polarity, if these distances are less than the values specified in Clause 28, unless the relevant part is adequately encapsulated; b) open-circuit at the terminal of any electronic component; c) short-circuit of capacitors, unless they comply with IEC 60384-14; d) short-circuit of any two terminals of an electronic component, other than an integrated circuit. This fault is not applied between the two circuits of an optocoupler; e) failure of triacs in the diode mode; f) failure of an integrated circuit. In this case the possible hazardous situations of the tool are assessed to ensure that safety does not rely on the correct functioning of such a component. All possible output signals are considered under fault conditions within the integrated circuit. If it can be shown that a particular output signal is unlikely to occur, then the relevant fault is not considered. Components such as thyristors and triacs are not subjected to fault condition f). Fault condition f) is applied to encapsulated and similar components if the circuit cannot be assessed by other methods. NOTE Microprocessors are examples of integrated circuits. Positive temperature coefficient resistors (PTC’s) are not short-circuited if they are used within their manufacturer’s declared specification. In addition, each low-power circuit is short-circuited by connecting the low power point to the pole of the supply from which the measurements were made. For simulation of the conditions, the tool is operated under the conditions specified in Clause 12, but at rated voltage or at the most unfavourable voltage within the rated voltage range. When any of the fault conditions are simulated, the duration of the test is: – as specified in 12.4, but only if the fault cannot be recognized by the user, for example, change in temperature; – as specified in 18.8, if the fault can be recognized by the user, for example, when the motor stops; – until steady conditions are established, for circuits continuously connected to the supply mains, for example, stand-by circuits. In each case, the test is ended if interruption of the supply occurs within the tool. 18.10.3 If safety of the tool depends upon the operation of a miniature fuse-link complying with IEC 60127-3 during any of the fault conditions specified in 18.10.2, the test is repeated but with the miniature fuse-link replaced by an ammeter. If the current measured – does not exceed 2,1 times the rated current of the fuse-link, the circuit is not considered to be adequately protected and the test is carried out with the fuse-link short-circuited; – is at least 2,75 times the rated current of the fuse-link, the circuit is considered to be adequately protected; Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI – is between 2,1 times and 2,75 times the rated current of the fuse-link, the fuse-link is short-circuited and the test is carried out • for the relevant period or for 30 s, whichever is the shorter, for quick acting fuse- links; • for the relevant period or for 2 min, whichever is the shorter, for time lag fuse-links. In case of doubt, the maximum resistance of the fuse-link has to be taken into account when determining the current. Other fuses are considered to be intentionally weak parts in accordance with 18.2. NOTE The verification whether the fuse-link acts as a protecting device is based on the fusing characteristics specified in IEC 60127-3, which also gives the information necessary to calculate the maximum resistance of the fuse-link. 18.10.4 Tools incorporating electronic devices shall be so designed that, in the event of a failure in the electronic equipment, this shall not result in a hazard. Compliance is checked by operating the tool for 1 min, at a voltage equal to the rated voltage or the mean value of the voltage range, at no-load with the electronic device short-circuited. The test is then repeated with the electronic device open-circuited. Following the tests of 18.10.1 to 18.10.4, the tool shall show no damage due to fire, mechanical damage impairing safety and protection against electric shock. Any current flowing through protective impedance shall not exceed the limits specified in 9.1. Where the tool incorporates a device for limiting speed should the electronic device fail to operate, the tool is considered to have withstood the test when the said speed-limiting device operates during the test. 18.11 Switches or other devices for motor reversal shall withstand the stresses occurring when the sense of rotation is reversed under running conditions where such a reversal is possible in normal use. Compliance is checked by the following test: The tool is operated at a voltage equal to rated voltage, or at the upper limit of the rated voltage range, at no-load; the device for reversing the sense of rotation being in such a position that the rotor rotates in one direction at full speed. The direction of the rotation is then reversed, without the device resting in an intermediate "off" position. This operation sequence is performed 25 times. After the test, the switch shall have no electrical or mechanical failure. 18.12 A class I tool employing class II construction (see 5.10) or a class II tool shall be able to operate under extreme overload conditions without impairing protection against electric shock. Compliance is checked by the following test on a separate sample. All fuses, thermal cut-outs, overload protectors and the like specified in 18.1 that are accessible to the user without the aid of a tool shall be shorted. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI The sample is connected to a minimum 12 kVA circuit. The tool is loaded to 160 % of normal load current for either 15 min or until the tool open-circuits or flame appears. If the tool will not operate at 160 %, the tool is stalled for 15 min or until the tool open-circuits or flame appears. If either condition occurs, immediately de-energise the tool and, if flames appear, extinguish with CO2 extinguisher. The leakage current between live parts and accessible parts, measured in accordance with Clause 13, is monitored throughout the test and after the test until leakage current has stabilized or decreases. Leakage current shall not exceed 2 mA. After the tool is cooled to room temperature, an electric strength test per Clause 15 is performed between live parts and accessible parts as follows: – If a tool does not operate after 15 min, apply a 1 500 V electric strength test. – If a tool operates after 15 min, apply a 2 500 V electric strength test. 19 Mechanical hazards 19.1 Moving and other dangerous parts shall, as far as is compatible with the use and mode of function of the tool, be so arranged or enclosed that, in normal use, adequate protection against injury is provided. Protective enclosures, covers, guards and the like shall possess adequate mechanical strength for their intended purpose. They shall not be removable without the aid of a tool. When used as protection of the working element, the guard shall have an easily accessible means of accurate adjustment with the objective of minimizing access to the dangerous parts. or obstructing the operator's view, by transferring heat, or causing other predictable hazards. All working elements, including special features or attachments intended as part of the tool, shall be secured so that they cannot create dangers during normal use by moving, or being released, out of the normal working constraints of the tool. NOTE 1 Such dangers might be caused by vibration, reversal of motion, or electric braking. Compliance is checked by inspection, by the tests of Clause 20 and by means of a test using the standard test finger shown in Figure 1. It shall not be possible to touch dangerous moving parts with this finger. This test is not applicable for dust collection openings with the dust collection devices removed, as they are tested in accordance with 19.3. NOTE 2 In some cases, specified in the relevant part 2, a rigid test finger with the same dimensions of the test finger in Figure 1, but without any articulation, is used. 19.2 Accessible parts likely to be touched during normal use shall be free from sharp edges, burrs, flashes and the like. Compliance is checked by inspection. 19.3 It shall not be possible to reach the moving parts with the provisions for dust collection removed, if any. Compliance is checked by a test with the rigid finger shown in Figure 1. It shall not be possible to touch dangerous moving parts with the test finger through dust collection openings after the removing of the removable provisions. 19.4 Tools shall have adequate grasping surfaces to ensure safe handling during use. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Compliance is checked by inspection. 19.5 Tools shall be designed and constructed to allow, where necessary, a visual check of the contact of the cutting tool with the workpiece. Compliance is checked by inspection. 19.6 For all tools where the relevant part 2 requires the tool to be marked with the rated no- load speed, the no-load speed of the spindle at rated voltage or at the upper limit of the rated voltage shall not exceed 110 % of the rated no-load speed. Compliance is checked by measuring the speed of the spindle after the tool has been operating for 5 min at no-load. 20 Mechanical strength 20.1 Tools shall have adequate mechanical strength, and shall be so constructed that they withstand such rough handling as may be expected in normal use. Compliance is checked by the tests specified in 20.2, 20.3 and 20.4. Following the tests, the tool shall withstand an electric strength test as specified in Clause 15, and shall show no damage which could impair compliance with this standard; in particular, live parts shall not have become accessible, as specified in Clause 9. Damage to the finish, small dents which do not reduce creepage distances or clearances below the values specified in 28.1, or small chips which do not adversely affect protection against shock or moisture are neglected. The function of mechanical safety devices shall not be impaired thereby. Cracks not visible to the naked eye and surface cracks in fibre-reinforced mouldings and the like are ignored. If a decorative cover is backed by an inner cover, a fracture of the decorative cover is neglected when the inner cover withstands the test after removal of the decorative cover. 20.2 Blows are applied to the tool by means of the spring-operated impact test apparatus according to Clause 5 of IEC 60068-2-75. The spring is so adjusted that it causes the hammer to strike with an impact energy as shown in Table 4. Table 4 – Impact energies Parts to be tested Impact energy Nm Brush caps 0,5 ± 0,05 1,0 ± 0,05 Other parts Three blows are applied to every point of the enclosure which is likely to be weak. Where necessary, blows are also applied to protective devices, handles, levers, knobs and the like. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Compliance is checked by the following test: 21 Construction EN 60745-1:2006 20.3 A hand-held tool shall withstand being dropped three times on a concrete surface from a height of 1 m. The sample shall be positioned to vary the point of impact. 20.4 Brush holders and their caps shall have adequate mechanical strength. Compliance is checked by inspection and, in case of doubt, by removing and replacing the brushes 10 times, the torque applied when tightening the cap being as shown in Table 5. Table 5 – Test torques Blade width of test screwdriver Torque mm Nm 0,4 Up to and including 2,8 0,5 Over 2,8 up to and including 3,0 0,6 Over 3,0 up to and including 4,1 0,9 Over 4,1 up to and including 4,7 1,0 Over 4,7 up to and including 5,3 1,25 Over 5,3 up to and including 6,0 After this test, the brush holder shall show no damage impairing its further use, the thread, if any, shall not be damaged and the cap shall show no cracks. The blade width of the test screwdriver shall be as large as possible, but shall not exceed the length of the recess in the cap. If, however, the thread diameter is smaller than the length of the recess, the blade width shall not exceed this said diameter. The torque shall not be applied in jerks. 20.5 For all tools that are likely to cut into concealed wiring or their own cord, handles and grasping surfaces, as specified in the instruction manual, shall have adequate mechanical strength in order to provide insulation between the grasping area and the output shaft. A separate sample, at the discretion of the manufacturer, is to be subjected to a single impact on each handle and each recommended grasping surface. The impacts are carried out from a height of 1 m onto a concrete surface followed by an electric strength test according to Clause 15 using 1 250 V a.c. between the grasping surfaces in contact with foil and the output shaft of the tool. 21.1 Tools which can be adjusted to suit different voltages, or to different speeds, shall be so constructed that accidental changing of the setting is unlikely to occur, if such a change might result in a hazard. Compliance is checked by inspection and by manual test. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 21.2 Tools shall be so constructed that accidental changing of the setting of control devices is unlikely to occur. Compliance is checked by manual test. 21.3 It shall not be possible to remove parts which ensure the required degree of protection against moisture without the aid of a tool. Compliance is checked by manual test. 21.4 If handles, knobs and the like are used to indicate the position of switches or similar components, it shall not be possible to fix them in a wrong position if this might result in a hazard. Compliance is checked by inspection and by manual test. 21.5 Replacement of a flexible cable or cord requiring the moving of a switch which acts also as a terminal for external conductors shall be possible without subjecting internal wiring to undue stress; after repositioning the switch, and before reassembling the tool, it shall be possible to verify whether the internal wiring is correctly positioned. Compliance is checked by inspection and by manual test. 21.6 Wood, cotton, silk, ordinary paper and similar fibrous or hygroscopic material shall not be used as insulation, unless impregnated. Insulating material is considered to be impregnated if the interstices between the fibres of the material are substantially filled with a suitable insulant. Compliance is checked by inspection. 21.7 Asbestos shall not be used in the construction of tools. Compliance is checked by inspection. 21.8 Driving belts shall not be relied upon to provide the required level of insulation. This requirement does not apply if the tool incorporates a special design of belt which prevents inappropriate replacement. Compliance is checked by inspection. 21.9 Insulating barriers of class II tools, and parts of class II tools which serve as supplementary insulation or reinforced insulation, and which might be omitted during reassembly after servicing, shall either: – be fixed in such a way that they cannot be removed without being seriously damaged; or − be so designed that they cannot be replaced in an incorrect position, and that, if they are omitted, the tool is rendered inoperable or manifestly incomplete. Compliance is checked by inspection and by manual test. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Servicing includes replacement of components such as supply cords and switches. This requirement is met if the barrier is so fixed that it can only be removed by breaking or cutting. Fixing by means of rivets is allowed, provided that these rivets need not be removed when replacing the brushes, capacitors, switches, non-detachable flexible cables and cords and the like. Fixing by means of an adhesive is only allowed if the mechanical strength of the joint is equal to that of the barrier. An adequate internal lining of insulation material, or an adequate internal insulating coating on metal enclosures, is considered to be an insulating barrier provided that the coating cannot easily be removed by scraping. For class II tools, a sleeve on an insulated internal conductor, other than the core of an external flexible cable or cord, is considered to be an adequate insulating barrier, if it can only be removed by breaking or cutting, or if it is clamped at both ends. Ordinary lacquering on the inside of metal enclosures, varnished cambric, flexible resin- bonded paper, or the like are not considered to be insulating barriers. 21.10 Inside the tool, the sheath (jacket) of a flexible cable or cord shall only be used as supplementary insulation where it is not subject to undue mechanical or thermal stresses. Compliance is checked by inspection. 21.11 Any assembly gap with a width greater than 0,3 mm in supplementary insulation shall not be coincidental with any such gap in basic insulation, neither shall any such gap in reinforced insulation give direct access to live parts. Compliance is checked by inspection and measurement. 21.12 Class I tools shall be so constructed that, should any wire, screw, nut, washer, spring or similar part become loose or fall out of position, it cannot become so disposed that accessible metal is made live. Class II tools or class II constructions shall be so constructed that, should any such part become loose or fall out of position, it cannot become so disposed that creepage distances or clearances over supplementary insulation or reinforced insulation are reduced to less than 50 % of the values specified in 28.1. Class II tools or class II constructions, other than those of the all-insulated type, shall be provided with insulating barriers between accessible metal and motor parts and other live parts. For class I tools, this requirement can be met by the provision of barriers, or by fixing the parts adequately, and by providing sufficiently large creepage distances and clearances. It is not to be expected that two independent parts will become loose or fall out of position at the same time. For electrical connections, spring washers are not considered to be adequate for preventing the loosening of the parts. Wires are considered as likely to become free from terminals or soldered connections, unless they are held in place near to the terminal or termination, independent of the terminal connection or solder. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Short rigid wires are not regarded as liable to come away from a terminal, if they remain in position when the terminal screw is loosened. Compliance is checked by inspection, by measurement and by manual test. 21.13 Supplementary insulation and reinforced insulation shall be so designed or protected that they are not likely to be impaired by deposition of dirt, or by dust resulting from wear of parts within the tool, to such an extent that creepage distances or clearance are reduced below the values specified in 28.1. Ceramic material not tightly sintered and similar materials, and beads alone, shall not be used as supplementary insulation or reinforced insulation. Parts of natural or synthetic rubber used as supplementary insulation shall be resistant to ageing, or be so arranged and dimensioned that creepage distances are not reduced below the values specified in 28.1, even if cracks occur. Insulating material in which heating conductors are embedded serves as basic insulation, and shall not be used as reinforced insulation. Compliance is checked by inspection, by measurement and, for rubber, by the following test: Parts of rubber are aged at a temperature of (100 ± 2) °C for 70 h. After the test, the samples are examined, and shall show no crack visible to the naked eye. NOTE In case of doubt with regard to materials other than rubber, special tests may be made. 21.14 Tools shall be so constructed that internal wiring, windings, commutators, slip rings and the like, and insulation in general, are not exposed to oil, grease or similar substances. If the construction necessitates that insulation be exposed to oil or grease or similar substance, as in gears and the like, the oil or grease or substance shall have adequate insulating properties so that compliance with the standard is not impaired, and shall have no effect on insulation. Compliance is checked by inspection and by the tests of this standard. 21.15 It shall not be possible to gain access to brushes without the aid of a tool. Screw-type brush-caps shall be so designed that, when tightening, two surfaces are clamped together. Brush-holders, which retain the brushes in position by means of a locking device, shall be so designed that the locking does not depend upon the brush-spring tension, if the loosening of the locking device might make accessible metal parts live. Screw-type brush-caps, which are accessible from the outside of the tool, shall be of insulating material, or be covered with insulating material of adequate mechanical and electrical strength; they shall not project beyond the surrounding surface of the tool. Compliance is checked by inspection and by manual test, the properties of the insulating material being verified: – by the tests of 20.2 and 20.4 for screw-type brush-caps which are accessible from the outside of the tool; – by the tests specified for supplementary insulation for class I tools and class III tools; – by the tests specified for reinforced insulation for class II tools. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 21.16 Tools employing liquid systems shall protect the user against the increased risk of shock due to the presence of liquid under conditions of normal use and the faults of the liquid system. Tools employing liquid systems shall be either: • of class III construction; • of class I or class II construction and be provided with a residual current device and comply with 14.4, 14.5 and 14.6; or • of class I or class II construction and be designed for use in combination with an isolating transformer and comply with 14.4 and 14.5. Compliance is checked by inspection. 21.17 Switches and reset buttons on non-self-resetting controls shall be so located that accidental operation is unlikely to occur. Compliance is checked by inspection, and by the following test: The tool is connected to the power supply, placed in any possible position and dragged across a horizontal surface. Inadvertent operation of the switch shall not then occur. 21.18 Tools, other than those provided with a flexible shaft, shall be fitted with a mains switch which can be switched off by the user without releasing his grasp on the tool. When a switch has a locking arrangement to lock it in the “on” position, the requirement in 21.18 is considered as being met provided the switch unlocks automatically when the trigger or actuating member is actuated. Compliance is checked by inspection and by manual test. 21.18.1 Where there is a risk associated with continued operation, the switch shall not have any locking device to lock it in the “on” position and it shall not remain in the “on” position when the trigger is released. This shall be stated in the relevant part 2. 21.18.2 Where there is a risk associated with inadvertent starting, the switch shall have a locking device to lock it on the “off” position. This shall be stated in the relevant part 2. 21.19 Tools shall be so designed that the protection against electric shock is not affected when screws intended for replacement from the outside during routine servicing are replaced by screws having a greater length. Compliance is checked by inserting longer screws, without appreciable force, after which creepage distances and clearances between live parts and accessible metal parts shall not have been reduced below the values specified in 28.1. 21.20 If the tool is marked with the first numeral of the IP system, the relevant requirements of IEC 60529 shall be fulfilled. Compliance is checked by making the relevant tests. 21.21 Tools shall be so designed that in normal use there is no risk of electric shock from charged capacitors when touching the pins of the plug. Capacitors, having a rated capacitance less than or equal to 0,1 μF, are not considered to entail a risk of electric shock. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI This requirement does not apply to capacitors complying with the requirements for protective impedance specified in 9.1 and 21.36. Compliance is checked by the following test, which is made 10 times. The tool is operated at rated voltage. The tool switch, if any, is then moved to the "off" position and the tool is disconnected from the supply by means of the plug. One second after disconnection, the voltage between the pins of the plug is measured with an instrument which does not appreciably affect the value to be measured. The voltage shall not exceed 34 V. 21.22 Non-detached parts, which provide the necessary degree of protection against electric shock, moisture, or contact with moving parts, shall be fixed in a reliable manner, and shall withstand the mechanical stress occurring in normal use. Snap-in devices used for fixing such parts shall have an obvious locked position. The fixing properties of snap-in devices used in parts which are likely to be removed during servicing shall not deteriorate. Compliance is checked by the following tests. Parts which are likely to be removed during servicing are disassembled and assembled 10 times before the test is carried out. Servicing includes replacement of the supply cord. The tool is at room temperature. However, in cases where compliance may be affected by temperature, the test is also carried out immediately after the tool has been operated under the conditions specified in Clause 12. The test is applied to all parts which are likely to be detachable, whether or not they are fixed by screws, rivets, or similar parts. A force is applied without jerks for 10 s in the most unfavourable direction to those areas of the cover or part which are likely to be weak. The force is as follows: – push force 50 N; – pull force a) if the shape of the part is such that the fingertips cannot easily slip off 50 N; b) if the projection of the part which is gripped is less than 10 mm in the direction of removal 30 N. The push force is applied by means of a rigid test finger similar in dimensions to the standard test finger shown in Figure 1. The pull force is applied by a suitable means such as a suction cup, so that the test results are not affected. While the pull test of a) or b) is being applied, the test fingernail shown in Figure 7 is inserted in any aperture or joint with a force of 10 N. The fingernail is then slid sideways with a force of 10 N; it is not twisted or used as a lever. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI If the shape of the part is such that an axial pull is unlikely, no pull force is applied, but the test fingernail shown in Figure 7 is inserted in any aperture or joint with a force of 10 N, and is then pulled for 10 s by means of the loop with a force of 30 N in the direction of removal. If the cover or part is likely to be subjected to a twisting force, a torque as detailed below is applied at the same time as the pull or push force: – for major dimensions up to and including 50 mm 2 Nm; – for major dimensions over 50 mm 4 Nm. This torque is also applied when the test fingernail is pulled by means of the loop. If the projection of the part which is gripped is less than 10 mm, the above torque is reduced to 50 % of the value. Parts shall not become detached, and they shall remain in the locked position. 21.23 Handles, knobs, grips, levers and the like shall be fixed in a reliable manner so that they will not work loose in normal use, if loosening might result in a hazard. Compliance is checked by inspection, by manual test, and by trying to remove the handle, knob, grip or lever applying, for 1 min, a 30 N axial force either pushing or pulling. 21.24 Storage hooks and similar devices for flexible cords shall be smooth and well rounded. Compliance is checked by inspection. 21.25 Current-carrying parts and other parts, the corrosion of which might result in a hazard, shall be resistant to corrosion under normal conditions of use. Compliance is checked by verifying that, after the tests of Clause 30, the relevant parts show no sign of corrosion. Stainless steel and similar corrosion-resistant alloys and plated steel are considered to be satisfactory for the purpose of this requirement. NOTE Examples of causes of corrosion are the incompatibility of materials and effects of heating. 21.26 Void 21.27 Tools other than class II, having parts where reliance is placed upon safety extra-low voltage to provide the necessary degree of protection against electric shock, shall be so designed that the insulation between parts operating at safety extra-low voltage and other live parts complies with the requirements for double insulation or reinforced insulation. Compliance is checked by the tests specified for double insulation or reinforced insulation. 21.28 Parts separated by protection impedance shall comply with the requirements for double insulation or reinforced insulation. Compliance is checked by the tests specified for double insulation or reinforced insulation. 21.29 Void 21.30 Shafts of operating knobs, handles, levers and the like shall not be live unless the shaft is not accessible when the knob, handle, lever and the like is removed. Compliance is checked by inspection and by applying the test finger as specified in 9.2 after removal of the knob, handle, lever, or the like, even with the aid of a tool. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 21.31 For constructions other than those of class III, handles, levers and knobs which are held or actuated in normal use shall not become live in the event of an insulation fault. If these handles, levers or knobs are of metal, and if their shafts or fixings are likely to become live in the event of a basic insulation fault, they shall either be adequately covered by insulating material, or their accessible parts shall be separated from their shafts or fixings by insulation. The covering or insulating material shall comply with the electric strength test in Clause 15, Table 2, item 4, but need not be supplementary insulation. Compliance is checked by inspection, and if necessary, by the tests specified for insulation. 21.32 For all tools that are likely to cut into concealed wiring or their own cord, handles and grasping surfaces, as specified in the instruction manual, shall be formed of insulating material or, when of metal, shall be either adequately covered by insulating material or their accessible parts shall be separated by insulating barrier(s) from accessible metal parts that may become live by the output shaft. These insulating barriers are not to be regarded as basic, supplementary or reinforced insulation. An insulated, stick type, auxiliary handle shall be provided with a flange having a height not less than 12 mm above the grasping surface between the grasping area and accessible parts that may become live by the output shaft. Compliance is checked by inspection and the tests of 20.5. 21.33 For class II tools, capacitors shall not be connected to accessible metal parts, and their casings, if of metal, shall be separated from accessible metal parts by supplementary insulation. This requirement does not apply to capacitors complying with the requirements for protective impedance specified in 9.1 and 21.36. Compliance is checked by inspection and by the tests specified for supplementary insulation. 21.34 Capacitors shall not be connected between the contacts of a thermal cut-out. Compliance is checked by inspection. 21.35 Lampholders shall be used only for the connection of lamps. Compliance is checked by inspection. 21.36 Protective impedance shall consist of at least two separate components, the impedance of which is unlikely to change significantly during the lifetime of the tool. If any one of the components is short-circuited or open-circuited, the values specified in 9.1 shall not be exceeded. Resistors complying with 14.1 of IEC 60065 and capacitors complying with 14.2 of IEC 60065 are considered to comply with this requirement. Compliance is checked by inspection and by measurement. 21.37 Air intake shall not enable the ingress of foreign bodies that could impair the safety. Compliance is checked by the following test: It shall not be possible to insert a steel ball of 6 mm diameter through the air intake openings other than those adjacent to the fan. 21.Z1 Tools, as identified in the relevant Part 2 or in case of tools not covered by a Part 2, where in normal use a considerable amount of dust hazardous to health is expected to be produced, shall have either: a) integral dust collection devices or b) devices which allow the connection of external dust collection equipment. If the solutions a) or b) are not reasonably practicable, the tool shall be designed in such a way that the dust is not thrown in the direction of the operator. Compliance is checked by inspection. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 22 Internal wiring 22.1 Wireways shall be smooth and free from sharp edges. Wires shall be protected so that they do not come into contact with burrs, cooling fins, etc., which may cause damage to the insulation of conductors. Holes in metal through which insulated wires pass shall be provided with bushings or, unless required otherwise in part 2, shall have smooth, well-rounded edges. A radius of 1,5 mm is considered to be well rounded. Wiring shall be effectively prevented from coming into contact with moving parts. Compliance is checked by inspection. 22.2 Internal wiring and electrical connections between different parts of the tool shall be adequately protected or enclosed. Compliance is checked by inspection. 22.3 Internal wiring shall be either so rigid and so fixed or so insulated that, in normal use, creepage distances and clearances cannot be reduced below the values specified in 28.1. The insulation, if any, shall be such that it cannot be damaged in normal use. Compliance is checked by inspection, by measurement, and by manual test. For insulated internal wiring, it is checked that either their insulation is electrically equivalent to the insulation of the cords complying with IEC 60227 or IEC 60245, or it complies with the following electric strength test. A voltage of 2 000 V is applied for 15 min between the conductor and metal foil wrapped around the insulation. There shall be no breakdown. When sleeving is used as supplementary insulation on internal wiring, it shall be retained in position by positive means. A sleeve is considered to be fixed by positive means if it can only be removed by breaking or cutting, or if it is clamped at both ends. Compliance is checked by inspection and by manual test. 22.4 Conductors identified by the colour combination green/yellow shall not be connected to terminals other than earthing terminals. Compliance is checked by inspection. 22.5 Aluminium wires shall not be used for internal wiring. Windings of a motor are not considered as internal wiring. Compliance is checked by inspection. 22.6 Stranded conductors shall not be consolidated by lead-tin soldering where they are subjected to contact pressure, unless the clamping means is so designed that there is no risk of bad contact due to cold flow of the solder. Consolidation of a stranded conductor by lead-tin soldering is allowed if spring terminals are used; securing the clamping screws alone is not considered adequate. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Soldering of the tip of a stranded conductor is allowed. Compliance is checked by inspection. 23 Components 23.1 Components shall comply with the safety requirements specified in the relevant IEC standards, as far as they reasonably apply. If components are marked with their operating characteristics, the conditions under which they are used in the tool shall be in accordance with these markings, unless a specific exception is made. 23.1.1 Capacitors in auxiliary windings of motors shall be marked with their rated voltage and their rated capacitance. 23.1.2 Fixed capacitors for radio interference suppression shall comply with IEC 60384-14. 23.1.3 Small lampholders similar to E10 lampholders shall comply with the requirements for E10 lampholders; they need not accept a lamp with E10 cap complying with the current edition of Standard Sheet 7004-22 of IEC 60061. 23.1.4 Isolating transformers and safety isolating transformers shall comply with IEC 61558-1. 23.1.5 Appliance couplers other than those used for IPX0 tools shall comply with IEC 60309. Those used for IPX0 shall comply with IEC 60320. Where appliance couplers not standardized by IEC are used, the manufacturer shall inform the user in the instructions for use to connect the tool only by means of the appropriate connector specified by the manufacturer. 23.1.6 Automatic controls not complying with IEC 60730-1 shall be tested according to this standard, and additionally, according to 11.3.5 to 11.3.8 and Clause 17 of IEC 60730-1. Controls may be tested separately from the tool. The tests according to IEC 60730-1 are carried out under the conditions occurring in the tool. For the tests of Clause 17 of IEC 60730-1, the number of cycles to be used are: – for thermostats, 10 000 cycles of operation; – for temperature limiters, 1 000 cycles of operation; – for self-resetting thermal cut-out, 300 cycles of operation; – for non-self-resetting thermal cut-out which is manually reset, 10 cycles of operation. Automatic controls which comply with the requirements of IEC 60730-1, and which are used in accordance with their marking, are considered to meet the requirements of this standard (the term "marking" includes documentation and declaration as specified in Clause 7 of IEC 60730-1). The tests of Clause 17 of IEC 60730-1 are not carried out on automatic controls which operate during Clause 12, if the tool meets the requirements of this standard when they are short-circuited. A specific exception with regard to the testing of thermostats and temperature limiters is made in footnote b) of Table 1 of Clause 12. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 23.1.7 The testing of components which have to comply with other standards is, in general, carried out separately, according to the relevant standard as follows. If the component is marked and used in accordance with its marking, it is tested in accordance with its marking, the number of samples being that required by the relevant standard. In particular, components not mentioned in Table 1 of Clause 12 are tested as a part of that tool. 23.1.8 Where no IEC standard exists for the relevant component, or where the component is not marked, or is not used in accordance with its marking, the component is tested under the similar specification. 23.1.9 For capacitors connected in series with a motor winding, it is verified that, when the tool is operated at a voltage equal to 1,1 times rated voltage and under minimum load, the voltage across the capacitor does not exceed 1,1 times the rated voltage of the capacitor. 23.1.10 Mains switches shall have adequate breaking capacity, and shall be switches for 50 000 cycles of operation. Compliance is checked by inspection and by the following test: Mains switches are tested together with the tool at rated voltage or at the upper limit of the rated voltage range of the tool. The motor is then stalled, and the switch is operated 50 times, each "on" period being not more than 0,5 s, and each "off" period being not less than 10 s. If, in normal use, an electronic control device switches off the current before opening the main contacts, the number of operations is reduced to five, with the electronic control device short-circuited. After the test, the switch shall have no electrical or mechanical failure. Mains switches marked with individual ratings are also tested in accordance with IEC 61058-1. 23.1.11 Switches, which have not been separately tested and found to comply with IEC 61058-1 under the conditions occurring in the tool, shall comply with Annex I. The test of 17.2.4.4 of IEC 61058-1 is carried out for 50 000 cycles of operation. Switches intended for operation under no-load, and which can be operated only with the aid of a tool, are not subjected to the tests of Clause 17 of IEC 61058-1. This applies also to such switches operated by hand which are interlocked so that they cannot be operated under load, but switches without that interlock are subjected to the test of 17.2.4.4 for 100 cycles of operation. The tests of 17.2.4.4 of IEC 61058-1 are not carried out on a switch if the tool meets the requirements of this standard when the switch is short-circuited. 23.2 Tools shall not be fitted with – switches or automatic controls in flexible cords, however RCDs are allowed; Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI – devices which are designed to cause the protection device in the fixed wiring to operate in the event of a fault in the tool; – thermal cut-outs which can be reset by a soldering operation. Compliance is checked by inspection. 23.3 Overload protection devices shall be of the non-self-resetting type. Compliance is checked by inspection. 23.4 Plugs and socket-outlets used as terminal devices for heating elements, and plugs and socket-outlets for extra-low voltage circuits, shall not be interchangeable with plugs and socket-outlets listed in IEC 60884, and with connectors and tool inlets complying with the standard sheets of IEC 60320. Compliance is checked by inspection. 23.5 Motors connected to the supply mains, and having basic insulation which is inadequate for the rated voltage of the tool, shall comply with the requirements of Annex B. Compliance is checked by the tests of Annex B. 24 Supply connection and external flexible cords 24.1 Tools shall be provided with one of the following means of connection to the supply: – a supply cord with a plug, for tools rated in voltage or frequency for connection to public supplies; – a supply cord without a plug, if the tool is intended to be connected to non-public power supplies; – an appliance inlet having at least the same degree of protection against moisture as required for the tool, and having a locking device preventing inadvertent disconnection; – a supply cord not exceeding 0,5 m and fixed with an in-line connector (cable coupler) and its mating counterpart. The in-line connector shall have at least the same degree of protection against moisture as required for the tool. Compliance is checked by inspection and for locking devices with the pull test of 24.14. 24.2 Supply cords shall be assembled to the tool by one of the following methods: – type X attachment; – type Y attachment; – type Z attachment, only for exchange type tools, as allowed in part 2. Supply cords with type X and type Y attachment may be either ordinary flexible cords or special cords and only available from the manufacturer or his service agent. A special cord may also include a part of the tool. Compliance is checked by inspection and, if necessary, by manual test. 24.3 Plugs shall not be fitted with more than one flexible cord. Compliance is checked by inspection. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 24.4 Supply cords shall be not lighter than: – class I tools Sheet 2 – I – class II tools Sheet 2 – class III tools Sheet 2 – I – class II tools Sheet 2 – class III tools Sheet 2 – III Compliance is checked by measurement. EN 60745-1:2006 – ordinary tough rubber sheathed flexible cord (code designation 60245 IEC 53); – ordinary polyvinyl chloride sheathed flexible cord (code designation 60227 IEC 53). Polyvinyl chloride insulated flexible cords shall not be used for tools having external metal parts, the temperature rise of which exceeds 75 K during the test of Clause 12. Compliance is checked by inspection and measurement. If provided with a plug, power supply cords of single-phase tools having a rated current not exceeding 16 A shall be provided with a plug complying with IEC 60884 or IEC 60309. If plugs complying with IEC 60309 are fitted, the standard sheets to be applied are as follows: The body of the plug shall be of, or covered with, rubber, polyvinyl chloride or material having no less mechanical strength. Power supply cords of single-phase tools, having a rated current exceeding 16 A but not exceeding 63 A, and of multi-phase tools having a rated current not exceeding 63 A, shall be provided with a plug complying with IEC 60309, the standard sheets to be applied being as follows: – class I tools Sheet 2 – III according to current Two-pole plugs, appliance inlets and connectors for cable couplers and plugs to standard sheet 2 are allowed in class II tools. 24.5 Supply cords shall have a nominal cross-sectional area not less than those shown in Table 6. Table 6 – Minimum cross-sectional area of supply cord Rated current of the tool Nominal cross-sectional area mm2 A 0,75 Up to and including 6 Over 6 up to and including 10 1,5 Over 10 up to and including 16 2,5 Over 16 up to and including 25 Over 25 up to and including 32 Over 32 up to and including 40 Over 40 up to and including 63 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 24.6 For class I tools, the supply cord shall be provided with a green/yellow core; it shall be connected to the internal earthing terminal of the tool, and to the earthing contact of the plug. Compliance is checked by inspection. 24.7 Conductors of supply cords shall not be consolidated by lead-tin soldering where they are subject to contact pressure, unless the clamping means is so designed that there is no risk of a bad contact due to cold flow of the solder. Compliance is checked by inspection. The requirement may be met by using spring terminals. Securing the clamping screws alone is not considered adequate. 24.8 For all types of attachment, moulding together the supply cord to the enclosure or part of it shall not affect the insulation of the cord. Compliance is checked by inspection. 24.9 Inlet openings shall be provided with a bushing, or shall be so constructed that the protective covering of the supply cord can be introduced without risk of damage. Compliance is checked by inspection and by manual test. 24.10 Inlet bushings shall: – be so shaped as to prevent damage to the supply cord; – be reliably fixed; – not be removable without the aid of a tool. Compliance is checked by inspection and by manual test. 24.11 Void 24.12 Cord guards shall have adequate mechanical strength and shall retain these properties throughout extended normal use. Compliance is checked by the following test: The part of the tool comprising the cable entry, fitted with the cord guard and the flexible cable or cord for which the tool is designed, is fixed in the oscillating member of an apparatus similar to that shown in Figure 9. The sample is so mounted that the axis of oscillation is tangential to the outer surface of the part in which the cord guard is secured, and, when the oscillating member is at the middle of its travel, the axis of the cable or cord where it leaves the cord guard is vertical. A weight, having a mass equal to that of the tool, but not less than 2 kg or more than 6 kg, is attached to the cable or cord. The oscillating member is moved backwards and forwards through an angle of 90° (45° on either side of the vertical), the number of flexings being 20 000 and the rate of flexing 60 per min. A flexing is one movement, either backwards or forwards. After 10 000 flexings, the sample is turned through 90° about the centre line of the cord guard. After the test, the cord guard shall not have worked loose, and neither the cord guard nor the flexible cable or cord shall show any damage which could impair compliance with this Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI standard, except that not more than 10 % of the number of strands of each conductor may have been broken. Immediately after this test, the cord anchorage and the terminal screws are loosened, without removing the conductors of the flexible cable or cord. However, if the cord guard is clamped under the cord anchorage, the cord anchorage is not loosened. The tool is then lifted by the cord guard, without jerks, over a distance of approximately 500 mm in approximately 1 s, and replaced on a support. The operation is made 10 times. During this test, the cord guard shall not slip out of its location. 24.13 Flexible cables or cords of tools shall be protected against excessive bending at the inlet opening of the tool by means of a cord guard of insulating material. The guards shall be fixed in a reliable manner, and shall be of such a design that they project outside the tool for a distance beyond the inlet opening of at least five times the overall diameter of the cable or cord delivered with the tool. Compliance is checked by inspection, by measurement and by the following test: A tool designed for a power supply cord is fitted with a cord guard, the flexible cable or cord being approximately 100 mm longer than the guard. The tool is so held that the axis of the cord guard, where the cable or cord leaves it, projects upwards at an angle 45° to the horizontal when the cable or cord is free from stress. A mass equal to 10 D2 g is then attached to the free end of the cable or cord. D is the external diameter of the flexible cable supplied with the tool in mm. If the cord guard is temperature sensitive, the test is made at a temperature of (23 ± 2) °C. Immediately after the mass has been attached, the curvature of the cable or cord shall nowhere be less than 1,5 D. 24.14 Tools provided with a supply cord shall have cord anchorages so that the conductors are relieved from strain, including twisting, where they are connected within the tool, and that the insulation of the conductors is protected from abrasion. It shall not be possible to push the cord into the tool to such an extent that the cord, or internal parts of the tool, could be damaged. Compliance is checked by inspection, by manual test, and by the following test: The cord is subjected 25 times to a pull of the value shown in Table 7. The pulls are applied without jerks in the most unfavourable direction each time for 1 s. Immediately afterwards, the cord, other than that of an automatic cord reel, is subjected for 1 min to a torque of the value shown in Table 7. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Mass of tool kg Up to and including 1 Over 1 up to and including 4 Over 4 During the tests, the cord shall not be damaged. Compliance is checked by inspection. – replacement of the cord is easily possible; EN 60745-1:2006 Table 7 – Pull and torque value Pull Torque N Nm 0,1 0,25 0,35 After the tests, the cord shall not have been longitudinally displaced by more than 2 mm, and the conductors shall not have moved over a distance of more than 1 mm in the terminals, nor shall there be appreciable strain at the connection. Creepage distances and clearances shall not be reduced below the value specified in 28.1. For the measurement of the longitudinal displacement, a mark is made on the cord while it is subjected to the pull, at a distance of approximately 2 cm from the cord anchorage or other suitable point, before starting the tests. After the tests, the displacement of the mark on the cord in relation to the cord anchorage or other point is measured while the cord is subjected to the pull. 24.15 Cord anchorages shall either be so arranged that they are only accessible with the aid of a tool, or be so designed that the cord can only be fitted with the aid of a tool. 24.16 For type X attachments, cord anchorages shall be so designed or located that: – it is clear how the relief from strain and the prevention of twisting are to be obtained; – they are suitable for the different types of cord which may be connected, unless the tool is so designed that only one type of cord can be fitted; – the cord cannot touch the clamping screws of the cord anchorage, if these screws are insulation; – the cord is not clamped by a metal screw which bears directly on the cord; – at least one part of the cord anchorage is securely fixed to the tool, unless it is part of the specially prepared cord; – screws, if any, which have to be operated when replacing the cord, do not serve to fix any other component, unless, when omitted or incorrectly mounted, they render the tool cannot be removed without the aid of a tool during the replacement of the cord; – in the case of labyrinths, these labyrinths cannot be bypassed in such a way that the test of 24.14 is not withstood; – glands shall not be used as cord anchorages for power supply cords; – for class I tools, they are of insulating material or are provided with an insulating lining, if otherwise an insulation fault on the cord could make accessible metal parts live; – for class II tools, they are of insulating material, or, if of metal, are insulated from accessible metal parts by insulation complying with the requirements for supplementary insulation. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI If, for type X attachment, the cord anchorage comprises one or more clamping member(s) to which pressure is applied by means of one or more nuts engaging with studs, which are securely attached to the tool, the cord anchorage is considered to have one part securely fixed to the tool, even if the clamping member(s) can be removed from the studs. If, however, the pressure on the clamping member(s) is applied by means of one or more screws engaging either with separate nuts, or with a thread in a part which is integral with the tool, the cord anchorage is not considered to have one part securely fixed to the tool, unless one of the clamping members itself is fixed to the tool, or the surface of the tool is of insulating material and so shaped that it is obvious that surface is one of the clamping member(s) (see Figure 6). Compliance is checked by inspection, and by the test of 24.14 under the following conditions. The tests are first made with the lightest permissible type of cord of the smallest cross- sectional area specified in 25.2, and then with the next heavier type of cord of the largest cross-sectional area specified, unless the tool is so designed that only one type of cord can be fitted. Tools, for which a specially prepared cord is used, are tested with the cord as delivered. The conductors are introduced into the terminals, the terminal screws, if any, being tightened just sufficiently to prevent the conductors from easily changing their position. The cord anchorage is used in the normal way, the clamping screws, if any, being tightened with a torque equal to two-thirds of that specified in 27.1. Screws of insulating material bearing directly on the cord are fastened with two-thirds of the torque specified in column I of Table 9; the length of the slot in the screw head being taken as the nominal diameter of the screw. 24.17 For type Y and Z attachments, cord anchorage shall be adequate. Compliance is checked by the test of 24.14, which is made with the cord as delivered. 24.18 For type X attachment, production methods such as tying the cord into a knot, or tying the ends with string, are not allowed. Compliance is checked by inspection. 24.19 The insulated conductors of the supply cord shall be insulated from accessible metal parts by insulation complying with the requirements for basic insulation for class I tools, and complying with the requirements for supplementary insulation for class II tools. This insulation shall consist of: – a separate insulating lining fixed to the cord anchorage; – a sleeve or grommet fixed to the cord; or – for class I tools, the sheath of the sheathed cord. Compliance is checked by inspection. 24.20 The space for the supply cables or the supply cord provided inside, or as a part of the tool for type X attachment: – shall be so designed as to permit checking, before fitting the cover, if any, that the conductors are correctly connected and positioned; – shall be so designed that covers, if any, can be fitted without risk of damage to the supply conductors or their insulation; Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI – shall be so designed that the uninsulated end of the conductor, should it become free from a terminal, cannot come into contact with accessible metal parts, unless the cord is provided with terminations that are unlikely to slip free of the conductor. Compliance is checked by inspection and, for type X attachment, by an installation test with following additional test. For pillar terminals where the conductors are not separately clamped at a distance of 30 mm or less from the terminal, and for other terminals with screw clamping, the clamping screws or nuts are loosened in turn. Without removing the conductor from the conductor space, a force of 2 N is applied to the wire in any direction and adjacent to the terminal, screw or stud. The uninsulated end of the conductor shall not then come into contact with accessible metal parts or any other metal part connected thereto. For pillar terminals, where the conductors are separately clamped at a distance of 30 mm or less from the terminal, the tool is considered to meet the requirement that the uninsulated end of the conductor must not come into contact with accessible metal parts. 24.21 Appliance inlets shall: – be so located or enclosed that live parts are not accessible during insertion or removal of the connector; – be so placed that the connector can be inserted without difficulty; – connector when in any position of normal use on a flat surface. Compliance is checked by inspection and, with regard to the first requirement, by means of the standard test finger shown in Figure 1, for tool inlets other than those standardized in IEC 60320. Tools provided with appliance inlets complying with IEC 60320 are considered to comply with the first requirement. 25 Terminals for external conductors 25.1 Tools with type X attachments, except those with specially prepared cord, shall be provided with terminals in which connection is made by means of screws, nuts, or equally effective devices. Screw-type terminals in accordance with IEC 60998-2-1, screwless terminals in accordance with IEC 60998-2-2 and clamping units in accordance with IEC 60999-1 are considered to be equally effective devices. Screws and nuts shall not serve to fix any other component, except that they may also clamp internal conductors, if these are so arranged that they are unlikely to be displaced when fitting the supply conductors. Compliance is checked by inspection. For tools with type X attachments, soldered connections may be used for the connection of external conductors, provided that the conductor is so positioned or fixed that reliance is not placed upon the soldering alone to maintain the conductor in position, unless barriers are provided so that creepage distances and clearances between live parts and other metal parts cannot be reduced to less than 50 % of the values specified in 28.1, should the conductor become free at the soldered joint. For type Y and type Z attachments, soldered, welded, crimped and similar connections may be used for the connection of external conductors; moreover, for class II tools, the conductor shall be so positioned or fixed that reliance is not placed upon the soldering, crimping, or Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI welding alone to maintain the conductor in position, unless barriers are provided so that creepage distances and clearances between live parts and other metal parts cannot be reduced to less than 50 % of the values specified in 28.1, should the conductor become free at the soldered or welded joint, or slip out of the crimped connection. It is not to be expected that two independent fixings will become loose at the same time. Conductors connected by soldering are not considered to be adequately fixed, unless they are held in place near to the termination, independently of the solder; but "hooking in" before soldering is, in general, considered to be a suitable means for maintaining the conductors of a power supply cord other than a tinsel cord in position, provided the hole through which the conductor is passed is not unduly large. The terminals of a component (such as a switch) built into the tool may be used as terminals intended for external conductors. Conductors connected to terminals or terminations by other means are not considered to be adequately fixed, unless an additional fixing is provided near the terminal or termination; this additional fixing, in the case of stranded conductors, clamps both the insulation and the conductor. Compliance is checked by inspection and by measurement. 25.2 Terminals for type X attachment, except those with specially prepared cords, shall allow the connection of conductors having nominal cross-sectional areas as shown in Table 8, unless the tool is so designed that only one type of cord can be fitted, in which case the terminals shall be suitable for the connection of that cord. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Up to and including 6 Over 6 up to and including 10 Over 10 up to and including 16 Over 16 up to and including 25 Over 25 up to and including 32 Over 32 up to and including 40 Over 40 up to and including 63 EN 60745-1:2006 Table 8 – Nominal cross-sectional area of conductors Rated current of tool Nominal cross-sectional area of flexible cables and cords mm2 A 0,75 and 1 1 and 1,5 1,5 and 2,5 2,5 and 4 4 and 6 6 and 10 10 and 16 Compliance is checked by inspection, by measurement and by fitting cables or cords of the smallest and largest cross-sectional areas specified. Terminals for supply cord shall be suitable for their purpose. Compliance is checked by inspection and by applying a pull of 5 N to the connection. After the test, the connections shall show no damage which could impair compliance with this standard. 25.3 For tools with type X attachments, terminals shall be so fixed that, when the clamping means is tightened or loosened, the terminal does not work loose, internal wiring is not subjected to stress, and creepage distances and clearances are not reduced below the values specified in 28.1. Compliance is checked by inspection, and by the test of 9.6 of IEC 60999-1, the torque applied being, however, equal to two-thirds of the torque specified in Table 4 of that standard. Terminals may be prevented from working loose by fixing with two screws, by fixing with one screw in a recess, so that there is no appreciable play, or by other suitable means. The requirement for fixation of terminals does not preclude the provision of supply terminals on switches, or similar device in a recess if, after connection of the supply cable, and after re-positioning of the switch or similar device in its recess, it can be verified by inspection that these components and the supply cable are, after re-assembly of the tool, in the correct position. Covering with sealing compound without other means of locking is not considered to be sufficient. Self-hardening resins may, however, be used to lock terminals which are not subject to torsion in normal use. 25.4 For tools with type X attachments, terminals shall be so designed that they clamp the conductor between metal surfaces with sufficient contact pressure, and without damage to the conductor. Compliance is checked by inspection of the terminals and of the conductors after the test of 25.3. 25.5 For tools with type X attachments, except those with specially prepared cords, terminals shall not require special preparation of the conductor in order to effect correct Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI connection, and they shall be so designed or placed that the conductor cannot slip out when clamping screws or nuts are tightened. Compliance is checked by inspection of the terminals and of the conductors after the test of 25.3. The term "special preparation of the conductor" covers soldering of the strands, use of cable lugs, formation of eyelets, etc., but not the reshaping of the conductor before its introduction into the terminal, or the twisting of a stranded conductor to consolidate the end. Conductors are considered to be damaged if they show deep or sharp indentations. 25.6 Terminals of the pillar type shall be so located that the end of a conductor introduced into the hole is visible, or can pass beyond the threaded hole for a distance at least equal to half the nominal diameter of the screw, or 2,5 mm, whichever is the greater. Compliance is checked by inspection and by measurement. 25.7 For type X attachments, the terminals shall be clearly recognizable and accessible after opening the tool. All terminals shall be located behind one cover, or one part of the enclosure. Compliance is checked by inspection. 25.8 Terminal devices shall not be accessible without the aid of a tool, even if their live parts are not accessible. Compliance is checked by inspection and by manual test. 25.9 Terminal devices of tools with type X attachment shall be so located or shielded that should a wire of a stranded conductor escape when the conductors are fitted, there is no risk of accidental connection between live parts and accessible metal parts and, in the case of class II tools, between live parts and metal parts separated from accessible metal parts by supplementary insulation only. Compliance is checked by the following test: An 8 mm length of insulation is removed from the end of a flexible conductor having a nominal cross-sectional area as specified in 24.5. One wire of the stranded conductor is left free, and the other wires are fully inserted into and clamped in the terminal. The free wire is bent, without tearing the insulation back, in every possible direction, but without making sharp bends around barriers. The free wire of a conductor connected to a live terminal shall not touch any metal part which is accessible, or is connected to an accessible metal part or, for class II tools, any metal part which is separated from accessible metal parts by supplementary insulation only. The free wire of a conductor connected to an earthing terminal shall not touch any live part. 26 Provision for earthing 26.1 Accessible metal parts of class I tools, which may become live in the event of an insulation fault, shall be permanently and reliably connected to an earthing terminal or termination within the tool, or to the earthing contact of the tool inlet. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI The printed conductors of printed circuit boards shall not be used to provide continuity of the protective earthing circuit. Earthing terminals and earthing contacts shall not be electrically connected to the neutral terminal. Class II and class III tools shall have no provision for earthing. If accessible metal parts are screened from live parts by metal parts which are connected to the earthing terminal or termination, or to the earthing contact, they are not, for the purpose of this requirement, regarded as likely to become live in the event of an insulation fault. Accessible metal parts, which are separated from live parts by double insulation or by reinforced insulation, are not considered likely to become live in the event of an insulation fault. Metal parts behind a decorative cover which does not withstand the test of Clause 20 are considered to be accessible metal parts. Compliance is checked by inspection. 26.2 The clamping means of earthing terminals shall be adequately locked against accidental loosening, and it shall not be possible to loosen them without the aid of a tool. Screw clamping terminals complying with Clause 25 or screwless terminals in accordance with IEC 60998-2-2 are considered to comply with the requirements of this clause. For specifically prepared cords, terminals complying with IEC 60760 are considered to comply with the requirements of this clause. tests specified in IEC 60998-2-2. 26.3 If detachable parts have an earth connection, this connection shall be made before the current-carrying connections are established when placing the part in position, and the current-carrying connections shall be separated before the earth connection is broken when removing the part. For tools with supply cords, the arrangement of the terminals, or the length of the conductors between the cord anchorage and the terminals, shall be such that the current-carrying conductors become taut before the earthing conductor, if the cord slips out of the cord anchorage. Compliance is checked by inspection and by manual test. 26.4 All parts of the earthing terminal intended for the connection of external conductors shall be such that there is no risk of corrosion resulting from contact between these parts and the copper of the earthing conductor, or any other metal in contact with these parts. Parts which may transmit current in the event of an insulation fault, other than parts of a metal frame or enclosure, shall be of coated or uncoated metal having adequate resistance to corrosion. If such parts are of steel, they shall be provided at the essential areas with an electroplated coating having a thickness of at least 5 μm. Parts of coated or uncoated metal, which are only intended to provide or to transmit contact pressure, shall be adequately protected against rusting. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Examples of parts which may transmit current in the event of an insulation fault, and parts which are only intended to provide or to transmit contact pressure are shown in Figure 8. If the body of the earthing terminal is a part of a frame or enclosure of aluminium or aluminium alloy, precautions shall be taken to avoid the risk of corrosion resulting from contact between copper and aluminium or its alloys. Parts of copper alloys containing at least 58 % copper for parts that are worked cold, and at least 50 % copper for other parts, and parts of stainless steel containing at least 13 % chrome, are considered to be sufficiently resistant to corrosion. Parts subjected to a treatment such as chromate conversion coating are in general not considered to be adequately protected against corrosion, but they may be used to provide or to transmit contact pressure. The essential areas of steel parts are, in particular, those transmitting current. In evaluating such areas, the thickness of the coating in relation to the shape of the part has to be taken into account. In case of doubt, the thickness of the coating is measured as described in ISO 2178 or in ISO 1463. Compliance is checked by inspection, by measurement, by manual test and by the test of 30.1. 26.5 The connection between the earthing terminal or earthing contact, and parts required to be connected thereto, shall be of low resistance. Compliance is checked by the following test: A current derived from a source having a no-load voltage not exceeding 12 V (a.c. or d.c.) and equal to 1,5 times rated current of the tool, or 25 A, whichever is the greater, is passed between the earthing terminal or earthing contact, and each of the accessible metal parts in turn. The voltage drop between the earthing terminal of the tool or the earthing contact of the tool inlet, and the accessible metal part is measured, and the resistance calculated from the current and this voltage drop. In no case shall the resistance exceed 0,1 Ω. In case of doubt, the test is carried out until steady conditions have been established. The resistance of the flexible cord is not included in the resistance measurement. Care is taken that the contact resistance between the tip of the measuring probe and the metal part under test does not influence the test results. 27 Screws and connections 27.1 Fixings, and electrical connections, the failure of which may impair compliance with this standard, shall withstand the mechanical stresses occurring in normal use. Screws used for this purpose shall not be of metal which is soft or liable to creep, such as zinc or aluminium. Such screws, when of insulating material, shall have a nominal diameter of at least 3 mm; they shall not be used for any electrical connection. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Screws transmitting electrical contact pressure shall screw into metal. Screws shall not be of insulating material if their replacement by a metal screw could impair supplementary insulation or reinforced insulation. Screws which may be removed when replacing a supply cord having a type X attachment, or when undertaking user maintenance, shall not be of insulating material if their replacement by a metal screw could impair basic insulation. NOTE Earthing connections are an example of electrical connections. Compliance is checked by inspection and by the following test: The screws or nuts are tightened and loosened: – 10 times for screws in engagement with a thread of insulating material; – five times for nuts and other screws. Screws in engagement with a thread of insulating material are completely removed and reinserted each time. When testing terminal screws and nuts, a flexible conductor of the largest cross-sectional area specified in 25.2 is placed in the terminal. The test is made by means of a suitable test screwdriver, spanner, or key applying a torque as shown in Table 9, the appropriate column being: – for metal screws without heads, if the screw when tightened does not protrude from the hole.......................................................................................... I – for other metal screws and for nuts .................................................................. II – for screws of insulating material: • having a hexagonal head with the dimension across flats exceeding the overall thread diameter; or • with a cylindrical head and a socket for a key, the socket having a cross-corner dimension exceeding the overall thread diameter; or • with a head having a slot or cross slots, the length of which exceeds 1,5 times the overall thread diameter ............................................................... II – for other screws of insulating material .............................................................. III Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Up to and including 2,8 Over 2,8 up to and including 3,0 Over 3,0 up to and including 3,2 Over 3,2 up to and including 3,6 Over 3,6 up to and including 4,1 Over 4,1 up to and including 4,7 Over 4,7 up to and including 5,3 Over 5,3 The conductor is moved each time the screw or nut is loosened. Compliance is checked by inspection. Compliance is checked by inspection. EN 60745-1:2006 Table 9 – Torque for testing screws and nuts Nominal diameter of screw Torque Nm mm I II III 0,4 0,4 0,2 0,5 0,5 0,25 0,5 0,6 0,3 0,6 0,8 0,4 0,6 1,2 0,7 0,9 1,8 0,8 1,0 2,0 0,8 − 1,25 2,5 During the test, no damage impairing the further use of the fixing or electrical connections shall occur. The shape of the blade of the test screwdriver is to fit the head of the screw to be tested. The screws and nuts are not to be tightened in jerks. 27.2 Electrical connections shall be so designed that contact pressure is not transmitted through insulating material which is liable to shrink or to distort, unless there is sufficient resiliency in the metallic parts to compensate for any possible shrinkage or distortion of the insulating material. Ceramic material is not liable to shrink or to distort. 27.3 Space-threaded (sheet metal) screws shall not be used for the connection of current- carrying parts, unless they clamp these parts directly in contact with each other, and are provided with a suitable means of locking. Thread-cutting (self-tapping) screws shall not be used for the electrical connection of current- carrying parts, unless they generate a full-form standard machine screw thread. Such screws shall not, however, be used if they are likely to be operated by the user or installer, unless the thread is formed by a swageing action. Thread-cutting and space-threaded screws may be used to provide earthing continuity, provided that it is not necessary to disturb the connection in normal use, and that at least two screws are used for each connection. 27.4 Screws, which make a mechanical connection between different parts of the tool, shall be secured against loosening, if they also make electrical connections. This requirement does not apply to screws in the earthing circuit if at least two screws are used for the connection, or if an alternative earthing circuit is provided. Spring washers and the like may provide satisfactory security. Sealing compound which softens on heating provides satisfactory security only for screw connections not subject to torsion in normal use. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Rivets used for electrical connections shall be secured against loosening if these connections are subject to torsion in normal use. A non-circular shank or an appropriate notch may be sufficient to comply with this requirement. This requirement does not imply that more than one rivet is necessary for providing earthing continuity. Compliance is checked by inspection and by manual test. 28 Creepage distances, clearances and distances through insulation 28.1 Creepage distances and clearances shall not be less than the values in millimetres shown in Table 10. The values specified in the table do not apply to cross-over points of motor windings. If a resonance voltage occurs between the point where a winding and a capacitor are connected together, and metal parts which are separated from live parts by basic insulation only, the creepage distance and clearance shall not be less than the values specified for the value of the voltage imposed by the resonance, these values being increased by 4 mm in the case of reinforced insulation. Compliance is checked by measurement. For tools provided with an appliance inlet, the measurements are made with an appropriate connector inserted; for tools with type X attachment, they are made with supply conductors of the largest cross-sectional area specified in 25.2, and also without conductors; for other tools, they are made on the tool as delivered. For tools provided with belts, the measurements are made with the belts in place, and the devices intended for varying the belt tension adjusted to the most unfavourable position within their range of adjustment, and also with the belts removed. Movable parts are placed in the most unfavourable position; nuts and screws with non- circular heads are assumed to be tightened in the most unfavourable position. The clearances between terminals and accessible metal parts are also measured with the screws or nuts unscrewed as far as possible, but the clearances shall then be not less than 50 % of the value shown in Table 10. Distances through slots or openings in external parts of insulating material are measured to metal foil in contact with the accessible surface; the foil is pushed into corners and the like by means of the standard test finger of Figure 1, but it is not pressed into openings. If necessary, a force is applied to any point on bare conductors, other than those of heating elements, to any point on uninsulated metal capillary tubes of thermostats and similar devices, and to the outside of metal enclosures, in an endeavour to reduce the creepage distances and clearances while taking the measurements. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Distances Clear- mm Creepag edistanc ance e 1,0 1,5 1,0 − Between live parts of different polarity a: – if protected against deposition of dirt b – if not protected against deposition of dirt – if lacquered or enamelled windings – for positive temperature coefficient (PTC) resistors including their connecting wires, if protected against deposition of moisture or dirt b 1,0 2,0 1,0 − 1,0 1,0 1,5 1,0 − 1,0 1,5 2,0 1,0 − Between live parts and other metal parts over basic insulation: – if protected against deposition of dirt b • if of ceramic material, pure mica and the like • if of other material – if not protected against deposition of dirt – if the live parts are lacquered or enamelled windings – at the end of tubular sheathed-type heating elements − − − − − − Between metal parts separated by supplementary insulation EN 60745-1:2006 Table 10 – Minimum creepage distances and clearances Dimensions in millimetres Other tools Working voltage Class III tools Working voltage Working voltage >250 V and ≤440 ≤130 V >130 V and ≤250 V V Clear- Clear- Creepag Clear- Creepag edistanc Creepag ance ance e distance ance e distance e 2,0 3,0 3,0 − 2,0 4,0 3,0 − 2,0 2,5 2,0 1,0 2,0 3,0 2,0 1,0 1,0 1,5 1,5 1,0 1,0 2,0 1,5 1,0 2,5 c 3,0 4,0 2,0 1,0 e 1,0 1,0 1,5 1,5 1,0 1,0 1,5 2,0 1,5 1,0 2,5 c 2,5 c 3,0 2,0 1,0 d − − − − − − − − − − Between live parts and other metal parts over reinforced insulation: – if the live parts are lacquered or enamelled windings or protected against deposition of dirt – for other live parts not protected against deposition of dirt − − 6,0 8,0 6,0 8,0 5,0 5,0 5,0 8,0 − − − − 4,0 4,0 2,5 2,5 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Table 10 (continued) a The clearances specified do not apply to the air gap between the contacts of thermal controls, overload protection devices, switches of micro-gap construction, and the like, or to the air gap between the current- carrying members of such devices where the clearance varies with the movement of the contacts. b In general, the interior of a tool having a reasonably dust-proof enclosure is considered to be protected against deposition of dirt, provided the tool does not generate dust within itself; hermetic sealing is not required. c If the parts are rigid and located by mouldings, or if the design is such that there is no likelihood of a distance being reduced by distortion or movement of the parts, this value may be reduced to 2,0 mm. d If protected against deposition of dirt. e If over ceramic, pure mica and the like, protected against deposition of dirt. The force is applied by means of the test finger of Figure 1, and has a value of: – 2 N for bare conductors and for uninsulated capillary tubes of thermostats and similar devices; – 30 N for enclosures. The way in which creepage distances and clearances are measured is indicated in Annex A. If a barrier is interposed, and if it is in two parts which are not cemented together, the creepage distance is also measured through the joint. If a barrier is interposed, clearances are measured over the barrier or, if the barrier is in two parts with mating surfaces which are not cemented together, through the joint. For tools having parts with double insulation where there is no metal between basic insulation and supplementary insulation, the measurements are made as though a metal foil were present between the two insulations. When assessing creepage distances and clearances, the effect of insulating lining of metal enclosures or covers is taken into consideration. Means provided for fixing the tool to a support are considered to be accessible. For conductive patterns on printed circuit boards, except at their edges, the values in the table between parts of different potential may be reduced, as long as the peak value of the voltage stress does not exceed: – 150 V per mm with a minimum distance of 0,2 mm, if protected against the deposition of dirt; – 100 V per mm with a minimum distance of 0,5 mm, if not protected against the deposition of dirt. When the limits mentioned above lead to higher values than those of the table, the values of the table apply. For peak voltages exceeding 50 V, the reduced creepage distances only apply if the Proof Tracking Index (PTI) of the printed circuit board, measured as in Annex G, is greater than These distances may be reduced further, provided that the tool complies with the requirements of Clause 18 when the distances are short-circuited in turn. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Creepage distances and clearances within optocouplers are not measured if the individual insulations are adequately sealed, and if air is excluded between individual layers of the material. For live parts of different polarity separated by basic insulation only, creepage distances and clearances smaller than those specified in the table are allowed, provided the requirements of Clause 18 are met if these creepage distances and clearances are short-circuited in turn. 28.2 For working voltages up to and including 130 V, the distance through insulation insulation, and not be less than 1,5 mm, if they are separated by reinforced insulation. For reinforced insulation used between windings and accessible metal, the distance through the insulation shall not be less than 1,0 mm. For working voltages over 130 V up to and including 250 V, the distance through insulation insulation, and not be less than 2,0 mm, if they are separated by reinforced insulation. This requirement does not apply if the insulation is applied in thin sheet form, other than mica or similar scaly material, and consists: – for supplementary insulation, of at least two layers, provided that any one of the layers withstands the electric strength test prescribed for supplementary insulation; – for reinforced insulation, of at least three layers, provided that, when any two of the layers are placed in contact, they withstand the electric strength test prescribed for reinforced insulation. The test voltage is applied between the outer surfaces of the layer, or of the two layers, as applicable. Moreover, this requirement does not apply if the supplementary insulation or the reinforced insulation is inaccessible, and meets one of the following conditions: – the maximum temperature rise determined during the tests of Clause 12 does not exceed the permissible value specified in 12.5; – the insulation, after having been conditioned for seven days (168 h) in a oven maintained at a temperature equal to 50 K greater than the maximum temperature rise determined during the tests of Clause 12, withstands an electric strength test as specified in Clause 15, this test being made on the insulation both at the temperature occurring in the oven, and at approximately room temperature. This requirement does not imply that the prescribed distance must be through solid insulation only; it may consist of thickness of solid insulation plus one or more air layers. Compliance is checked by inspection and by measurement. For optocouplers, the conditioning procedure is carried out at a temperature of 50 K in excess of the maximum temperature rise measured on the optocoupler during the tests of Clause 12 and Clause 18, the optocoupler being operated under the most onerous conditions which occur during these tests. 29 Resistance to heat, fire and tracking NOTE Annex J shows the selection and sequence of the tests of this clause. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 29.1 External parts of non-metallic material, parts of insulating material supporting live parts, including connections and parts of thermoplastic material providing supplementary insulation or reinforced insulation, the deterioration of which might cause the tool to fail to comply with this standard, shall be sufficiently resistant to heat. Compliance is checked by subjecting of the relevant parts to a ball-pressure test, which is made by means of the apparatus shown in Figure 5. Before starting the test, the part is maintained for 24 h in an atmosphere having a temperature between 15 °C and 35 °C, and a relative humidity between 45 % and 75 %. The part is supported so that its upper surface is horizontal and the spherical part of the apparatus is pressed against this surface with a force of 20 N. The thickness of the part under test shall be at least 2,5 mm. The required thickness may be obtained by using two or more sections of the part. The test is made in a heating cabinet at a temperature of (40 ± 2) °C plus the maximum temperature rise determined during the test of Clause 12, but it shall be at least: − for external parts (75 ± 2) °C; − for parts retaining live parts in position (125 ± 2) °C. Before the test is started, the test apparatus is brought to the temperature determined above. After 1 h, the apparatus is removed and the part is immediately immersed in cold water so that it is cooled to room temperature within 10 s. The diameter of the impression shall not exceed 2 mm. For coil formers, only those parts which support or retain in position terminals or terminations are subjected to the test. Unless otherwise specified, parts operating at safety extra-low voltage not exceeding 24 V are not considered to be live parts. The test is not made on parts of ceramic material. 29.2 Parts of non-metallic material shall be adequately resistant to ignition and to spread of fire. This requirement does not apply to decorative trims, knobs, and other parts not likely to be ignited or to propagate flames originating from inside the tool. Compliance is checked by subjecting parts of non-metallic material to the glow-wire test of IEC 60695-2-11, which is carried out at 550 °C. The glow-wire test is not carried out on parts of material classified at least HB40 according to IEC 60695-11-10, provided that the test sample was no thicker than the relevant part. Parts for which the glow-wire test cannot be carried out, such as those made of soft or foamy material, shall meet the requirements specified in ISO 9772 for category HBF material, the test sample being no thicker than the relevant part. 29.3 Insulating material, across which a tracking path may occur, shall have adequate resistance to tracking, taking into account the severity of its duty conditions. A tracking current may occur Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI – between live parts of different polarity; – between live parts and earthed metal parts; – across insulating material of commutators and brush-caps. All tools are considered to be normal duty unless otherwise stated in the relevant part 2. For parts of insulating material used under severe or extra-severe duty conditions, compliance is checked by the proof tracking test referred to in Annex G. For parts of insulating material used under normal duty conditions, and parts of ceramic material, no tracking test is made. For parts of insulating material used under severe duty conditions, the test voltage is 175 V. If the specimens do not withstand this test and there is no hazard other than fire, surrounding parts are subjected to the needle-flame test referred to in Annex F. For parts of insulating material used under extra-severe duty conditions, the test voltage is 250 V. If the specimens do not withstand this test, but withstand the test made with a test voltage of 175 V, and there is no hazard other than fire, surrounding parts are subjected to the needle-flame test referred to in Annex F. The needle-flame test is made on all parts of non-metallic material positioned within a distance of 50 mm from any place where a tracking path may occur, unless these parts are shielded by a separate barrier or enclosure from that tracking path, in which case the barrier or enclosure is subjected to the needle-flame test. 30 Resistance to rusting 30.1 Ferrous parts, the rusting of which might cause the tool to fail to comply with this standard, shall be adequately protected against rusting. Compliance is checked by the following test: All grease is removed from the parts to be tested by immersing them in a suitable degreasing agent for 10 min. The parts are then immersed for 10 min in a 10 % solution of ammonium chloride in water at a temperature of (20 ± 5) °C. Without drying, but after shaking off any drops, the parts are placed for 10 min in a box containing air saturated with moisture at a temperature of (20 ± 5) °C. After the parts have been dried for 10 min in a heating cabinet at a temperature of (100 ± 5) °C, their surfaces shall show no signs of rust. When using the liquids specified for the test, adequate precautions must be taken to prevent the inhalation of their vapours. Traces of rust on sharp edges and any yellowish film removable by rubbing are ignored. For small helical springs and the like, and for parts exposed to abrasion, a layer of grease may provide sufficient protection against rusting. Such parts are only subjected to the test if there is doubt about the effectiveness of the grease film, and the test is then made without previous removal of the grease. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 31 Radiation, toxicity and similar hazards 31.1 Tools shall not emit harmful radiation, or present a toxic or similar hazard. Compliance is checked by test. NOTE Test specifications are given in part 2, where necessary. 31.2 If the tool is fitted with a laser to indicate a cutting line or the like, the laser shall be of category II or lower, according to IEC 60825-1. Compliance is checked by inspection. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI ∅75 ∅50 E F 14° (20) (10) R = 4 ± 0,05 Key on angles: 0/−10 up to 25 mm: 0/−0,05 D Joints over 25 mm: ±0,2 E Stop face ′ tolerance. EN 60745-1:2006 Section A-A 20 ± 0,2 Section B-B A 5 ± 0,5 B C D ∅12 A A B B 37° R = 2 ± 0,05 G H IEC 2336/01 Material: metal, except where otherwise specified Linear dimensions in millimetres Tolerances on dimensions without specific tolerance: A Handle F Chamfer all edges ′ B Guard G Spherical on linear dimensions: C Insulating material H Cylindrical ° with a 0 ′ to +10 Both joints shall permit movement in the same plane and the same direction through an angle of 90 Figure 1 – Standard test finger Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI ∅ 25 ± 0,2 ∅ 10 S Key EN 60745-1:2006 15 0 -0,1 -0,05 -0,05 ∅ 4 0 ∅ 3 IEC 2337/01 Dimensions in millimetres Figure 2 − Test pin C S1 IEC 533/06 C Circuit of Figure 10 for the leakage current meter S Mains switch of the product under test 1 Accessible part 2 Inaccessible metal part 3 Basic insulation 4 Supplementary insulation 5 Reinforced insulation 6 Double insulation Figure 3 − Diagram for leakage current measurement at operating temperature for single-phase connection and three-phase tools suitable for single-phase supply Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI N Key A Spherical B Sample EN 60745-1:2006 C a b c IEC 534/06 Key C Circuit of Figure 10 for the leakage current meter 1 Accessible part 2 Inaccessible metal part 3 Basic insulation 4 Supplementary insulation 5 Three-phase supply 6 Double insulation Figure 4 − Diagram for leakage current measurement at operating temperature for three-phase connection R = 2,5 mm B A IEC 2340/01 Figure 5 − Ball-pressure test apparatus Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI IEC 553/01 IEC 554/01 Part of tool of insulating material and so-shaped that it obviously forms part of a cord clamp. One of the clamping measures is fixed to the tool. Acceptable constructions IEC 555/01 Screws passing through threaded holes in the tool (or screws passing through clearance holes in the tool and secured by nuts) are equally unacceptable. Unacceptable constructions Figure 6 − Schematic representation of cord anchorages Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 0,2 ± 0,02 M3 37° C ∅12 -0,05 ∅12 -0,05 R = 2 ± 0,05 ∅14 (10) 37° A A2:2 B EN 60745-1:2006 IEC 551/01 X X 2:1 Figure 7 – Test fingernail A Insulating material 7,6 B Spring diameter C C Loop Key M3 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI A B B A B B A IEC 2341/01 Key A Part providing earthing continuity B Part providing or transmitting contact pressure Figure 8 – Examples of parts of earthing terminals Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI D E F Key C Counterweight D Sample G Load EN 60745-1:2006 C 45° 45° X B A ≥ 300 mm G IEC 552/01 A Axis of oscillation B Oscillating frame E Adjustable carrier plate F Adjustable bracket Figure 9 − Flexing test apparatus Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI A Test terminals B RS 1 500 Ω RB 500 Ω CS 0,22 µF Supply source Points A and B are separately short-circuited to C. EN 60745-1:2006 Weighted touch current (perception/reaction) CS RS U2 = (peak value) R1 RB U1 U2 C1 IEC 1078/99 R1 10 000 Ω C1 0,022 µF Figure 10 – Circuit for measuring leakage currents D Z1 Z2 Z3 Z4 Z7 B Z5 Z6 A C Z8 IEC 550/01 A and B are points closest to the supply source where the maximum power delivered to external load does not exceed 15 W. These are low-power points. D is a point farthest from the supply source where the maximum power delivered to external load exceeds 15 W. The fault conditions a) to f) specified in 18.10.2 are applied individually to Z1, Z2, Z3, Z6 and Z7 where applicable. Figure 11 – Example of an electronic circuit with low-power points Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI  Material: pine wood 75 × 40 planed, glued and doweled EN 60745-1:2006 Dimensions in millimetres Figure Z1 - Test bench Figure Z2 - Positions of power tool and microphones for the hemispherical / cylindrical measurement surface Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI  X Key EN 60745-1:2006 Z Y Z Z Y Additional measurement position, if the transducer cannot be placed half way along the length of the handle for vibration isolated handles Figure Z3a) Hand grip position - hand grips around a cylindrical handle Z X Figure Z3b) Flat palm position - hand presses down onto a spherical hand grip Figure Z3 — Directions of vibration measurement Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex A (normative) Measurement of creepage distances and clearances A.1 Measurement of creepage distances and clearances The methods of measuring creepage distances and clearances, which are specified in 28.1, are indicated in cases 1 to 10 (see Figure A.1). These cases do not differentiate between gaps and grooves, or between types of insulation. The following assumptions are made: – a groove may have parallel, converging, or diverging sides; – any groove having diverging sides, a minimum width exceeding 0,25 mm, a depth exceeding 1,5 mm, and a width at the bottom equal to or greater than 1 mm, is regarded as an air gap across which no creepage path exists (case 8); – any corner including an angle less than 80° is assumed to be bridged with an insulating link of 1 mm width (0,25 mm for dirt-free situations), moved into the most unfavourable position (case 3); – where the distance over the top of a groove is 1 mm (0,25 mm for dirt-free situations) or more, no creepage distance exists across the air gap (case 2); – creepage distances and clearances measured between parts moving relative to each other are measured when these parts are placed in their most unfavourable stationary positions; – any air gap less than 1 mm wide (0,25 mm for dirt-free situations) is ignored in computing the total clearance. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Condition: Path under consideration includes a parallel or converging sided groove of any depth with a width less than 1 mm. Rule: Creepage distance and clearance are measured directly across the groove as shown. Case 1 Condition: Path under consideration includes a parallel sided groove of any depth equal to or more than 1 mm wide. Rule: Clearance is the "line of sight" distance. Creepage path follows the contour of the groove. Case 2 Condition: Path under consideration includes a V-shaped groove with internal angle of less than 80° and with a width greater than 1 mm. Rule: Clearance is the "line of sight" distance. Creepage path follows the contour of the groove but "short circuits" the bottom of the groove by 1 mm link (0,25 mm for dirt-free situations). Case 3 Clearance Creepage distance Figure A.1a – Clearance gap for parallel sided and V-shaped groove Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Condition: Path under consideration includes a rib. Rule: Clearance is the shortest direct path over the top of the rib. Creepage path follows the contour of the rib. Case 4 Condition: Path under consideration includes an uncemented joint with grooves less than 1 mm wide on either side (0,25 mm for dirt-free situations). Rule: Creepage and clearance is the “line of sight” distance shown. Case 5 Condition: Path under consideration includes an uncemented joint with grooves equal to or more than 1 mm wide each side. Rule: Clearance is the “line of sight” distance. Creepage path follows the contour of the grooves. Case 6 Clearance Creepage distance Figure A.1b – Clearance gap for rib and uncemented joint with groove Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Condition: Path under consideration includes an uncemented joint with a groove on one side less than 1 mm wide and the groove on the other side equal to or more than1 mm wide. Rule: Clearance and creepage path are as shown. Case 7 Condition: Path under consideration includes a diverging-sided groove equal to or greater than 1,5 mm deep and greater than 0,25 mm wide at the narrowest part and equal to or greater than 1 mm at the bottom. Rule: Clearance is the "line of sight" distance. Creepage path follows the contour of the groove. Case 3 also applies to the internal corners if they are less than 80°. Case 8 Clearance Creepage distance Figure A.1c – Clearance gap for uncemented joint and diverging-sided groove Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Gap between head of screw and wall of recess too narrow to be taken into account. Case 9 Gap between head of screw and wall of recess wide enough to be taken into account. Case 10 Clearance Creepage distance Figure A.1d – Clearance gap between wall and screw Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex B (normative) Motors not isolated from the supply mains and having basic insulation not designed for the rated voltage of the tool B.1 Scope B.1.1 This annex applies to motors having a working voltage not exceeding 42 V, not isolated from the supply mains, and having basic insulation not designed for the rated voltage of the tool. All clauses of this standard apply to these motors, unless otherwise specified in this annex. B.9 Protection against access to live parts B.9.1 Metal parts of the motor are considered to be bare live parts. B.12 Heating B.12.3 The temperature rise of the body of the motor is determined instead of the temperature rise of the windings. B.12.5 The temperature rise of the body of the motor, where it is in contact with insulating material, shall not exceed the values shown in Table 1 for the relevant insulating material. B.15 Electric strength B.15.3 The insulation between live parts of the motor and its other metal parts is not subjected to this test. B.18 Abnormal operation B.18.1 The test of 18.7 is not made. Tools are also subjected to the test of B.18.201. B.18.201 The tool is operated at rated voltage with each of the following defects: – short circuit of the terminals of the motor, including any capacitor incorporated in the motor circuit; – open circuit of the supply to the motor; – open circuit of any shunt resistor during operation of the motor. Only one defect is simulated at a time, the tests being made consecutively. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI B.21 Construction B.28.1 B A D Cp Components ___ original connection – – – short circuit ≈ open circuit A short circuit of the terminals of the motor B short circuit of the terminals of the rectifier C open circuit of the supply to the motor D open circuit of the shunt resistor EN 60745-1:2006 B.21.201 For class I tools incorporating a motor supplied by a rectifier circuit, the d.c. circuit shall be insulated from accessible parts of the tool by double insulation or reinforced insulation. Compliance is checked by the tests specified for double insulation and reinforced insulation. B.28 Creepage distances, clearances and distances through insulation The values specified in Table 10 do not apply to distances between live parts of the motor and its other metal parts. Parallel circuit Series circuit C C B A M M Cp IEC 558/01 IEC 559/01 Figure B.1 – Simulation of defects Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex C Void Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex D Void Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex E Void Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 5.4 Specified layer Severities Test procedure 9.3 Number of test specimens 11 Evaluation of test results Add: EN 60745-1:2006 Annex F (normative) Needle-flame test The needle-flame test is made in accordance with IEC 60695-11-5. For the purpose of this standard, the following modifications to clauses and subclauses of IEC 60695-11-5 apply. Description of the test apparatus In cases where burning or glowing particles might fall from the specimen onto an external surface underneath the tool, the test is made with a piece of white pine-wood board, approximately 10 mm thick, and covered with a single layer of tissue paper, positioned at a distance of 200 mm ± 5 mm below the place where the test flame is applied to the specimen. If the tool as a whole is tested, it is placed in its normal position of use above the pine-wood board, which is covered with a single layer of tissue paper. The duration of application of the test flame is 30 s. The test is made on one specimen. If the specimen does not withstand the test, the test is repeated on two further specimens, both of which shall then withstand the test. When a layer of tissue paper is used, there shall be no ignition of the tissue paper, or scorching of the white pine-wood board; a slight discoloration of the white pine-wood board being neglected. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Test specimen Test apparatus Basic test procedure Determination of erosion This clause does not apply. The number of specimens is five. This clause does not apply. EN 60745-1:2006 Annex G (normative) Proof tracking test The proof tracking test is made in accordance with IEC 60112. For the purpose of this standard, the following modifications to clauses and subclauses of IEC 60112 apply. The second paragraph, after NOTE 2, does not apply. The test solution A described in 7.3 is used. The test voltage referred to in 8.2 is adjusted to 175 V or 250 V, as appropriate. 10 Determination of proof tracking index (PTI) 11 Determination of comparative tracking index (CTI) Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex H Void Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex I (normative) Switches Switches which are tested with the tool shall comply with this standard and with the following clauses of IEC 61058-1, as modified. Unless otherwise specified, the tests are carried out on the switch incorporated in the tool. Before being tested in the tool, switches are operated 20 times without load. 8 Marking and documentation Switches are not required to be marked, except that incorporated switches shall be marked with the manufacturer's name or trade mark and the type reference. NOTE According to IEC 61058-1, an incorporated switch can be tested separately from the tool. 13 Mechanism This clause is applicable. NOTE The tests may be carried out on a separate sample. 15 Insulation resistance and dielectric strength 15.1 The dielectric strength of switches shall be adequate. Compliance is checked by the test of 15.3, the test being made immediately after the test of 14.3 of IEC 60745. For mechanical switches, the test is carried out across full disconnection and micro- disconnection only. For electronic switches, the test is carried out across full disconnection and micro- disconnection only on electronic switches with mechanical switching devices connected in series with the semiconductor switching device. For electronic switches, the tests are not carried out across protective impedances and poles interconnected by components. 15.2 This subclause is not applicable. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 17 Endurance 17.1.1 Addition: Switches in the tool are considered to be for declared specific loads. 17.1.2 The sequence of tests for all switches except electronic switches is as follows: − a test at accelerated speed as specified in 17.2.4.4; − a temperature-rise test in accordance with 16.2, with the exception that the temperature- rise test at the terminals is carried out at rated current and in an ambient temperature of 25 °C ± 10 °C; − a dielectric strength test in accordance with 15.3, with the exception that the specimens are not subjected to the humidity treatment before the application of the test voltage. The test voltage shall be 75 % of the corresponding test voltage specified in that subclause. 17.2.1.1 The switch shall be loaded at rated voltage under the conditions occurring in the tool. Circuits and contacts which are not intended for external loads are operated with the designated load. No electrical endurance tests are necessary for switches for 20 mA load as classified in 7.1.2.6. NOTE For a specific lamp load, it is recommended that the specimen be operated with loads that are used in the field rather than with synthetic loads. Forced cooling of the specific lamp load may be applied in order to ensure cold resistance for each operating cycle and shorten the test time. For electronic switches, the test circuit shall be as shown in Figure 19. The declared load shall be set at rated voltage before the electronic switch is inserted into the circuit. 17.2.1.2 This subclause is not applicable. 17.2.2.1 All tests are carried out at 25°C ± 10°C. 17.2.3.1 Items a) and b) are not applicable. 17.2.3.3 This subclause is not applicable. 17.2.3.4.2 This subclause is not applicable. 17.2.3.4.3 This subclause is not applicable. 17.2.4.1 This subclause is not applicable. 17.2.4.2 This subclause is not applicable. 17.2.4.3 This subclause is not applicable. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI 17.2.4.4 Test at accelerated speed (TC4) For all switches except electronic switches, the electrical conditions are those specified in 17.2.1. For electronic switches, the electrical conditions are those specified in Table 15. The thermal conditions are those specified in 17.2.2. The total number of operations shall be 50 000. The method of operation is that specified for accelerated speed in 17.2.3. 17.2.4.9 This subclause is not applicable. 20 Clearances, creepage distances, solid insulation and coatings of rigid printed board assemblies This clause is applicable for creepage distances and clearances for live parts of different potential only, for operational insulation and across full disconnection and micro- disconnection. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI External parts of non- Parts of insulating material metallic material supporting live parts, including connections Ball pressure test Ball pressure test ≥75 °C ≥125 °C (29.1) (29.1) Glow-wire test No tracking test Tracking test 175 V EN 60745-1:2006 Annex J (informative) Selection and sequence of the tests of Clause 29 Resistance to heat and fire Tools Other parts of non-metallic Thermoplastic material material providing supplementary or reinforced insulation Ball pressure test Ball pressure test ΔTmax + 40 K (29.1) No requirements 550 °C IEC 60695-2-11 (29.2) Resistance to tracking Tools Normal duty conditions Severe duty conditions Extra severe duty conditions Tracking test Annex G 250 V Annex G Failure Failure Tracking test 175 V Annex G Pass Needle-flame test on surrounding parts Annex F Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex K (normative) Battery tools and battery packs K.1 Scope This annex applies to rechargeable battery-powered motor-operated or magnetically driven tools and the battery packs for such tools. This annex applies to tools incorporating detachable, integral and separable battery packs. The maximum rated voltage for tools and battery packs is 75 V d.c. Battery tools covered by this annex are not considered to be class I, class II, or class III tools and therefore are not required to have basic, supplementary or reinforced insulation. Electric shock hazard is considered to exist only between parts of opposite polarity. Battery packs for tools covered under this annex intended to be charged by a non-isolated charger shall be evaluated by this annex and standard. When evaluating a battery pack for protection against electric shock, creepage distances, clearances and distances through insulation, the battery pack shall be fitted to the intended charger. All clauses of this standard apply unless otherwise specified in this annex. If a clause is stated in the annex, the requirements replace the requirements of the standard. For the purpose of the tools covered by this annex, the term “mains switch” as it appears in the standard is understood to refer to the power switch of the battery-operated tool. user, and this annex alone will not be sufficient to ensure all hazards are considered for these products’ “battery packs” . This annex does not apply to battery chargers which are covered by IEC 60335-2-29. K.2 Normative references This clause is applicable except as follows: Additional normative reference: IEC 61558-2-6:1997, Safety of power transformers, power supply units and similar – Part 2: Particular requirements for safety isolating transformers for general use Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI K.3 Terms and definitions For the purpose of this annex, the following definitions apply. K.3.201 battery pack assembly of one or more cells intended to provide electrical current to the tool K.3.201.1 detachable battery pack battery pack which is contained in a separate enclosure from the battery tool and is intended to be removed from the tool for charging purposes K.3.201.2 integral battery pack battery pack which is contained within the battery tool and is not removed from the battery tool for charging purposes. A battery pack that is to be removed from the battery tool for disposal or recycling purposes only is considered to be an integral battery pack K.3.201.3 separable battery pack battery pack which is contained in a separate enclosure from the battery tool and is connected to the battery tool by a cord K.3.202 fully charged battery pack battery pack which has been through at least two discharge and charge cycles with an interval of at least 2 h after each cycle in accordance with the manufacturer’s instructions K.3.203 non-isolated source voltage source in which the output is not isolated from the mains supply by means of a safety isolating transformer as specified in IEC 61558-1 and IEC 61558-2-6 K.3.204 hazardous voltage voltage between parts having an average value exceeding 60 V d.c. or 42,4 V peak when the peak-to-peak ripple exceeds 10 % of the average value K.3.205 power switch switch that controls the primary operating means of the tool K.5 General conditions for the tests K.5.7.1 This subclause is not applicable. K.5.7.2 Tools having more than one rated voltage are tested on the basis of the most unfavourable voltage. K.5.7.3 This subclause is not applicable. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI K.5.10 This subclause is not applicable. K.5.11 This subclause is not applicable. K.5.14 This subclause is not applicable. K.5.15 This subclause is not applicable. K.5.16 This subclause is not applicable. K.5.201 Unless otherwise specified, a fully charged battery pack shall be used for each test. K.5.202 When measuring voltage, the peak value of any superimposed ripple exceeding 10 % of the average value shall be included. Transient voltages are ignored, such as a temporary increase above rated voltage, for example after the battery pack is removed from the charger. K.7 Classification This clause is not applicable. K.8 Marking and instructions K.8.1 Battery tools and detachable or separable battery packs shall be marked with: − rated voltage(s) or rated voltage range(s), in volts; − symbol for nature of supply; − name or trade mark or identification mark of the manufacturer or responsible vendor; − model or type reference; − manufacturer’s address or country of origin; − any mandatory mark showing compliance with legislation by reference to this standard. Additional markings shall not give rise to misunderstanding. Compliance is checked by inspection. K.8.2 This subclause is not applicable. K.8.5 This subclause is not applicable. K.8.7 This subclause is not applicable. K.8.8 This subclause is not applicable. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI K.8.12.1.1 This subclause is applicable except as follows: Item 5) Service, is replaced by the following: 5) Battery tool use and care a) Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack. b) Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire. c) When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire. d) Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns. 6) Service a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. K.9 Protection against electric shock NOTE The title of this clause differs from that of the main standard. Battery tools and battery packs shall be so constructed and enclosed that there is adequate protection against electric shock. K.9.1 This subclause is not applicable. K.9.2 It shall not be possible to have two conductive, simultaneously accessible parts where the voltage between them is hazardous unless they are provided with protective impedance. In the case of protective impedance the short circuit current between the parts shall not exceed 2 mA for d.c. or 0,7 mA peak for a.c. and there shall not be more than 0,1 μF capacitance directly between the parts. Compliance for accessibility is checked by applying the test finger of Figure 1 to each conductive part. The test finger of Figure 1 is applied without any appreciable force through openings to any depth that the finger will permit, and it is rotated or angled before, during and after insertion to any position. If the opening does not allow entry of the finger, the force on the finger in the straight position is increased to 20 N and the test with the finger bent repeated. Contact with the test finger is determined with all detachable parts removed and the battery tool operated in any possible position of normal use. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Lamps located behind detachable covers are not removed, providing the lamp may be de- energized by means of a user operable plug, battery pack disconnection or a switch. K.9.3 This subclause is not applicable. K.9.4 This subclause is not applicable. K.10 Starting This clause is not applicable. K.11 Input and current This clause is not applicable. K.12 Heating K.12.1 Battery tools and battery packs shall not attain excessive temperatures. Compliance is checked by determining the temperature rise of the various parts under the following conditions: The tool is operated at no-load until maximum temperature is reached or the tool no longer operates due to the battery pack being discharged. During the test, thermal cut-outs and overload releases shall not operate. The temperature rises shall not exceed the values shown in Table K.1. Table K.1 – Maximum normal temperature rises for battery tools Parts Temperature rise K External enclosure, except handles held in normal use Handles, knobs, grips, and the like which, in normal use, are continuously held: − of metal − of porcelain or vitreous material − of molded material, rubber or wood Handles, knobs, grips, and the like which, in normal use, are held for short periods only (e.g. switches): − of metal − of porcelain or vitreous material − of molded material, rubber or wood Parts in contact with oil having a flash point of t °C t-50 K.12.2 to K.12.6 These subclauses are not applicable. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI K.13 Leakage current This clause is not applicable. K.14 Moisture resistance This clause is not applicable. K.15 Electric strength This clause is not applicable. K.17 Endurance This clause is not applicable. K.18 Abnormal operation EN 60745-1:2006 K.15.1 Materials providing insulation from electric shock shall be adequate. Compliance is checked by subjecting the insulating material for 1 min to 750 V with a substantially sinusoidal wave form having a frequency of 50 Hz or 60 Hz. This provision does not exclude the testing of the material as situated within the tool, providing care is taken to ensure that materials not under consideration are not subjected to the test voltage. This test applies only to materials which, if they were to fail to insulate, would subject the user to a shock hazard from a hazardous voltage. This test does not apply to materials that provide only a physical barrier to contact. As such, an uninsulated energized part shall be within 1,0 mm of the material surface to be considered for this requirement. K.15.2 This subclause is not applicable. K.16 Overload protection of transformers and associated circuits K.18.1 All tools when operating under battery power and their battery packs shall be so designed that the risk of fire or electric shock as a result of abnormal operation is obviated as far as is practical. Compliance is checked by the following tests. The battery tool and battery pack, as is appropriate, are to be placed on a soft wood surface layer of untreated 100 % cotton medical gauze. The test is to be conducted until failure or until the test sample returns to room temperature. A new sample can be used for each fault listed below. There shall be adequate protection against electric shock as defined in Clause K.9 and no charring or burning of the gauze or tissue paper shall result when a battery tool and battery pack are subjected to any one of the following fault conditions shown below in tests a) to f). Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Charring is defined as a blackening of the gauze caused by combustion. Discolouration of the gauze caused by smoke is acceptable. Thermal cut-outs and thermal overloads may operate during the above tests. In this case, the same test is to be repeated three more times, using three additional samples. The resistance for the short in items a), b), d), e) and f) shall not exceed 10 mΩ. a) The terminals of a detachable battery pack with exposed terminals are shorted. Battery pack terminals that can be contacted using either Figure 1 or Figure 2 probes are considered exposed. The means of shorting shall not attain excessive temperatures so as to char or ignite the tissue paper or gauze. b) The motor terminals are shorted. c) The motor rotor is locked. d) A cord provided between the separable battery pack and the battery tool shall be shorted at the point likely to produce the most adverse effects. e) A cord provided between the tool and the charger shall be shorted at the point likely to produce the most adverse effects. f) For battery tools a short is introduced between any two uninsulated parts of opposite polarity not in accordance with the spacings given in Clause K.28. K.18.2 to K.18.9 These subclauses are not applicable. K.18.12 This subclause is not applicable. K.19 Mechanical hazards K.19.201 If a tool is marked with a direction of movement, it shall not be possible to connect a battery pack such that the marking is not correct. K.20 Mechanical strength K.20.1 Battery tools and battery packs shall have adequate mechanical strength, and shall be so constructed that they withstand such rough handling as may be expected in normal use. Compliance is checked by the tests of 20.2 and K.20.3. Following the test, the battery tool and battery pack shall meet the requirements of Clauses K.9, K.19 and either K.18.1 f) or K.28.1. K.20.3 A battery tool with its battery pack attached, shall withstand being dropped three times on a concrete surface from a height of 1 m. The sample shall be positioned to vary the point of impact. For battery tools with detachable or separable battery packs, the test is repeated three more times without the battery pack attached to the tool. In addition, for detachable or separable battery packs the test is repeated three more times on the battery packs separately. New samples may be used for each series of three drops. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI K.20.4 This subclause is not applicable. K.21 Construction K.21.5 This subclause is not applicable. K.21.6 This subclause is not applicable. K.21.8 to K.21.16 These subclauses are not applicable. K.21.21 This subclause is not applicable. K.21.25 to K.21.34 These subclauses are not applicable. K.21.201 Tools shall not readily accept general purpose batteries (either primary or rechargeable). NOTE Examples of general purpose batteries are AA, C, D, etc. K.22 Internal wiring K.22.3 This subclause is applicable only for hazardous voltages. K.22.4 This subclause is not applicable. K.23 Components K.23.1.10 Power switches shall have adequate breaking capacity. Compliance is checked by subjecting a switch to 50 operations of making and breaking the locked output mechanism current of the fully charged battery-operated tool. Each “on” period has a duration of not more than 0,5 s and each “off” period has a duration of at least 10 s. After this test the power switch shall have no electrical or mechanical failure. If the switch operates properly in the on and off positions at the end of the test, it is considered to have no mechanical or electrical failures. K.23.1.11 Power switches shall withstand, without excessive wear or other harmful effect, the mechanical, electrical, and thermal stresses occurring in normal use. Compliance is checked by subjecting a switch to 6 000 cycles of operation making and breaking the current encountered in the fully charged battery tool operated at no-load. The switch is operated at a uniform rate of 30 operations per minute. During the test the switch shall operate correctly. After the test, inspection of the switch shall show no undue wear, no discrepancy between the position of the operating means and that of the moving contacts, no loosening of electrical or mechanical connections, no seepage of sealing compound. K.23.5 This subclause is not applicable. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI K.24 Supply connection and external flexible cords This clause is not applicable, except as follows: K.24.201 For battery tools with separable battery packs, the external flexible cable or cord shall have anchorages such that the conductors are relieved from strain, including twisting, where they are connected within the tool, and protected from abrasion. Compliance is checked by inspection. K.25 Terminals for external conductors This clause is not applicable. K.26 Provision for earthing This clause is not applicable. K.27 Screws and connections K.27.1 This subclause is applicable except as follows: the sixth paragraph and the accompanying note, which refers to earthing connections, are not applicable. K.28 Creepage distances, clearances and distances through insulation K.28.1 Creepage distances and clearances shall not be less than the values in millimetres shown in Table K.2. The clearances specified do not apply to the air gap between the contacts of thermal controls, overload protection devices, switches of micro-gap construction, and the like, or to the air gap between the current-carrying members of such devices where the clearances vary with the movement of the contacts. Creepages and clearances also do not apply to the construction of battery cells or the interconnections between cells in a battery pack. The values specified in Table K.2 do not apply to cross-over points of motor windings. For parts having a hazardous voltage between them, the sum total of the measured distances between each of these parts and their nearest accessible surface shall not be less than 1,5 mm clearance and 2,0 mm creepage. NOTE Figure K.1 provides clarification on the measurement method. Compliance is checked by measurement. The way in which creepage distances and clearances are measured is indicated in Annex A. For parts of different polarity, clearance and creepage distances less than those given in Table K.2 are acceptable if the shorting of the two parts does not result in the tool starting. NOTE The risk of fire due to spacings below the required values is covered by the requirements of 18.1. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Creepage Clearance Creepage distance – 2 N for bare conductors; – 30 N for enclosures. K.28.2 This subclause is not applicable. K.29 Resistance to heat, fire and tracking EN 60745-1:2006 Table K.2 – Minimum creepage distances and clearances between parts of opposite polarity Dimensions in millimetres ≤15 V >15 V and ≤32 V >32 V Clearance Creepage Clearance distance distance – 0,8 – 1,5 2,0 1,5 Distances through slots or openings in external parts of insulating material are measured to the metal foil in contact with the accessible surface; the foil is pushed into corners and the like by means of the standard test finger of Figure 1, but is not pressed into openings. The sum total of distances measured between parts operating at hazardous voltage and accessible surfaces is determined by measuring the distance from each part to the accessible surface. The distances are to be added together to determine the sum total. See Figure K.1. For the purpose of this determination, one of the distances shall be 1,0 mm or greater. See Annex A, cases 1 to 10. If necessary, a force is applied to any point on bare conductors and to the outside of metal enclosures, in an endeavour to reduce the creepage distances and clearances while taking the measurements. The force is applied by means of a test finger having a tip as shown in Figure 1 and has a value of: If a barrier is interposed, and if it is in two parts which are not cemented together, the creepage distance is also measured through the joint. If a barrier is interposed, clearances are measured over the barrier or, if the barrier is in two parts with mating surfaces which are not cemented together, through the joint. When assessing creepage distances and clearances, the effect of insulating lining of metal enclosures or covers is taken into consideration. Means provided for fixing the tool to a support are considered to be accessible. K.29.1 External parts of non-metallic material, the deterioration of which might cause the tool or battery pack to fail to comply with this annex, shall be sufficiently resistant to heat. Compliance is checked by subjecting of the relevant parts to a ball-pressure test, which is made by means of the apparatus shown in Figure 5. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI – for external parts (75 ± 2) °C. K.29.3 This subclause is not applicable. across the openings. a + b is the sum total as defined in K.28.1. EN 60745-1:2006 Before starting the test the part is maintained for 24 h in an atmosphere having a temperature between 15 °C and 35 °C, and a relative humidity between 45 % and 75 %. The part is supported so that its upper surface is horizontal and the spherical part of the apparatus is pressed against this surface with a force of 20 N. The thickness of the part under test shall be at least 2,5 mm. The required thickness may be obtained by using two or more sections of the part. The test is made in a heating cabinet at a temperature of (40 ± 2) °C plus the maximum temperature rise determined during the test of K.12, but it shall be at least: Before the test is started, the test apparatus is brought to the temperature determined above. After 1 h, the apparatus is removed and the part is immediately immersed in cold water so that it is cooled to room temperature within 10 s. The diameter of the impression shall not exceed 2 mm. The test is not made on parts of ceramic material. K.29.2 This subclause applies only to the external enclosure enclosing the current-carrying part of the tool or battery pack. a b IEC 535/06 Dimension a = distance from positive bare conductive part to the external surface as defined by foil stretched across the openings. Dimension b = distance from negative bare conductive part to the external surface as defined by foil stretched Figure K.1 – Measurement of clearances Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex L (normative) Battery tools and battery packs provided with mains connection or non-isolated sources L.1 Scope This annex applies to rechargeable battery-powered motor-operated or magnetically driven tools and the battery packs for such tools that are also operated and/or charged directly from the mains or a non-isolated source, including tools provided with integral battery chargers. This annex applies to tools incorporating detachable, integral and separable battery packs. The maximum rated voltages for tools are 250 V single phase a.c. or d.c. mains source and 75 V d.c. battery source. The maximum rated voltage for battery packs is 75 V d.c. Battery packs for tools covered under this annex intended to be charged by a non-isolated charger shall be evaluated by this annex and standard. When evaluating a battery pack for protection against electric shock, creepage distances, clearances and distances through insulation, the battery pack shall be fitted to the intended charger. All clauses of this standard apply unless otherwise specified in this annex. If a clause is stated in the annex, the requirements replace the requirements of the standard. For the purpose of the tools covered by this annex, the term “mains switch” as it appears in the standard is understood to refer to the power switch of the battery-operated tool. user and this annex alone will not be sufficient to ensure all hazards are considered for these products. This annex does not apply to battery chargers which are covered by IEC 60335-2-29. L.2 Normative references This clause is applicable except as follows: Additional normative reference: IEC 61558-2-6:1997, Safety of power transformers, power supply units and similar – Part 2: Particular requirements for safety isolating transformers for general use L.3 Terms and definitions For the purpose of this annex, the following definitions apply: L.3.201 battery pack assembly of one or more cells intended to provide electrical current to the tool Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI L.3.201.1 detachable battery pack battery pack which is contained in a separate enclosure from the battery tool and is intended to be removed from the tool for charging purposes L.3.201.2 integral battery pack battery pack which is contained within the battery tool and is not removed from the battery tool for charging purposes. A battery pack that is to be removed from the battery tool for disposal or recycling purposes only is considered to be an integral battery pack L.3.201.3 separable battery pack battery pack which is contained in a separate enclosure from the battery tool and is connected to the battery tool by a cord L.3.202 fully charged battery pack battery pack which has been through at least two discharge and charge cycles with an interval of at least 2 h after each cycle in accordance with the manufacturer’s instructions L.3.203 non-isolated source voltage source in which the output is not isolated from the mains supply by means of a safety isolating transformer as specified in IEC 61558-1 and IEC 61558-2-6 L.3.204 hazardous voltage voltage between parts having an average value exceeding 60 V d.c. or 42,4 V peak when the peak-to-peak ripple exceeds 10 % of the average value L.3.205 power switch switch that controls the primary operating means of the tool L.3.206 interconnecting cord external flexible cord provided as part of a complete tool for purposes other than connection to the supply mains NOTE A remote hand-held switching device, an external interconnection between two parts of a tool and a cord connecting an accessory to the tool or to a separate signalling circuit are examples of interconnecting cords. L.5 General conditions for the tests L.5.201 Unless otherwise specified, a fully charged battery pack shall be used for each test. L.5.202 When measuring voltage, the peak value of any superimposed ripple exceeding 10 % of the average value shall be included. Transient voltages are ignored, such as a temporary increase above rated voltage, such as after the battery pack is removed from the charger. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI L.7 Classification L.7.1 This subclause applies except that class III tools are not considered in this annex. L.8 Marking and instructions L.8.1 The first paragraph of this subclause is replaced by the following: Non-isolated sources that can supply a tool, or tools that can be supplied directly from the mains, shall be marked with the following. In the case of tools supplied directly from the mains, these markings shall include those for both mains and battery operation: – rated voltage(s) or rated voltage range(s), in volts; – symbol for nature of supply; – rated input, in watts, or rated current in amperes; – name or trade mark or identification mark of the manufacturer or responsible vendor; – model or type reference; – symbol for class II construction, for class II tools only; – manufacturer’s address or country of origin; – any mandatory mark showing compliance with legislation by reference to this standard. Compliance is checked by inspection. L.8.1.201 Tools, other than those that can be supplied directly from the mains, and detachable or separable battery packs shall be marked with: – rated voltage(s) or rated voltage range(s), in volts; – symbol for nature of supply; – name or trade mark or identification mark of the manufacturer or responsible vendor; – model or type reference; – manufacturer’s address or country of origin; – any mandatory mark showing compliance with legislation by reference to this standard. Additional markings shall not give rise to misunderstanding. Compliance is checked by inspection. L.8.12.1.1 This subclause is applicable except as follows: Item 5) Service, is replaced by the following: 5) Battery tool use and care a) Recharge only with the charger specified by the manufacturer. A charger that is suitable for one type of battery pack may create a risk of fire when used with another battery pack. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI b) Use power tools only with specifically designated battery packs. Use of any other battery packs may create a risk of injury and fire. c) When battery pack is not in use, keep it away from other metal objects, like paper clips, coins, keys, nails, screws or other small metal objects, that can make a connection from one terminal to another. Shorting the battery terminals together may cause burns or a fire. d) Under abusive conditions, liquid may be ejected from the battery; avoid contact. If contact accidentally occurs, flush with water. If liquid contacts eyes, additionally seek medical help. Liquid ejected from the battery may cause irritation or burns. 6) Service a) Have your power tool serviced by a qualified repair person using only identical replacement parts. This will ensure that the safety of the power tool is maintained. L.9 Protection against electric shock NOTE The title of this clause differs from that of the main standard. The requirements of 9.1 through 9.4 apply for all conditions along with the following addition: Addition: Tools covered by this annex and their battery packs shall be so constructed and enclosed that there is adequate protection against electric shock. The clause of the standard applies to tools when they are connected to the mains or are supplied by a non-isolated source. During the evaluation in this condition, battery packs are to be connected to the tool in the normal fashion. The tool is also evaluated with the battery pack removed if such removal can be accomplished without the use of a tool. L.9.1.201 For battery packs which may be disconnected from the tool and tools operated under battery power it shall not be possible to have two conductive, simultaneously accessible parts where the voltage between them is hazardous, unless they are provided with protective impedance. In the case of protective impedance the short circuit current between the parts shall not exceed 2 mA for d.c. or 0,7 mA peak for a.c. and there shall not be more than 0,1 μF capacitance directly between the parts. Compliance for accessibility is checked by applying the test finger of Figure 1 to each conductive part. The test finger of Figure 1 is applied without any appreciable force through openings to any depth that the finger will permit, and it is rotated or angled before, during and after insertion to any position. If the opening does not allow entry of the finger, the force on the finger in the straight position is increased to 20 N and the test with the finger bent repeated. Contact with the test finger is determined with all detachable parts removed and the battery tool operated in any possible position of normal use. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI L.10 Starting L.11 Input and current L.12 Heating L.13 Leakage current L.14 Moisture resistance L.15 Electric strength EN 60745-1:2006 Lamps located behind detachable covers are not removed, providing the lamp may be de- energized by means of a user operable plug, battery disconnection or a switch. This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. In the case of tools that can also charge the battery while performing their intended function, the test is conducted while charging a previously discharged battery pack. This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. In the case of tools that can also charge the battery pack while performing their intended function, they are tested with the charger connected and are operated at no-load until the tool stops operating due to the battery pack being discharged or until thermal stabilization is achieved, whichever occurs first. The test is repeated, allowing the battery pack to charge while the tool is not operating. This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. Care shall be taken that the premature failure of electronic devices does not prevent the application of the test voltage across insulation. If this is the case, electronic devices may be bypassed to enable the test to be conducted. L.16 Overload protection of transformers and associated circuits This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI L.17 Endurance This clause applies to tools capable of continuous operation when they are supplied directly from the mains or from a non-isolated source. Tools that are not capable of continuous operation shall be operated under battery power for the duration of the test but shall be evaluated for electric strength with their charger connected. L.18 Abnormal operation This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. L.18.201 All tools when operating only under battery power and their battery packs shall be so designed that the risk of fire or electric shock as a result of abnormal operation is obviated as far as is practical. Compliance is checked by the following tests. The battery tool and battery pack, as is appropriate, are to be placed on a soft wood surface covered by two layers of tissue paper; the battery tool and battery pack are to be covered by one layer of untreated 100 % cotton medical gauze. The test is to be conducted until failure or until the test sample returns to room temperature. A new sample can be used for each fault listed below. There shall be adequate protection against electric shock as defined in Clauses L.9 and L.13 and no charring or burning of the gauze or tissue paper shall result when a battery tool and battery pack are subjected to any one of the following fault conditions shown below in tests a) to f). Charring is defined as a blackening of the gauze caused by combustion. Discolouration of the gauze caused by smoke is acceptable. Thermal cut-outs and thermal overloads may operate during the above tests. In this case, the same test is to be repeated three more times, using three additional samples. The resistance for the short in items a), b), d), e) and f) shall not exceed 10 mΩ. a) The terminals of a detachable battery pack with exposed terminals are shorted. Battery pack terminals that can be contacted using either Figure 1 or Figure 2 probes are considered exposed. The means of shorting shall not attain excessive temperatures so as to char or ignite the tissue paper or gauze. b) The motor terminals are shorted. c) The motor rotor is locked. d) A cord provided between the separable battery pack and the battery tool shall be shorted at the point likely to produce the most adverse effects. e) A cord provided between the tool and the charger shall be shorted at the point likely to produce the most adverse effects. f) For battery tools a short is introduced between any two uninsulated parts of opposite polarity not in accordance with the spacings given in L.28.201. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI L.19 Mechanical hazards L.19.201 If a tool is marked with a direction of movement it shall not be possible to connect a battery pack such that the marking is not correct. L.20 Mechanical strength This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. L.20.201 With the battery connected, battery tools and battery packs shall have adequate mechanical strength, and shall be so constructed that they withstand such rough handling as may be expected in normal use. A battery tool with its battery pack attached, shall withstand being dropped three times on a concrete surface from a height of 1 m. The sample shall be positioned to vary the point of impact. For battery tools with detachable or separable battery packs, the test is repeated three more times without the battery pack attached to the tool. In addition for detachable or separable battery packs the test is repeated three more times on the battery packs separately. New samples may be used for each series of three drops. Following the test, the battery tool and battery pack shall meet the requirements of Clauses L.9, L.19, L.28.1 and either L.18.201 f) or L.28.201. L.21 Construction This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. L.22 Internal wiring This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. L.23 Components L.23.1.10 The subclause of the standard applies only to tools capable of performing their intended operation when connected to the mains or to a non-isolated source for those switches that control the primary operating means of the tool. L.23.1.10.201 Switches, other than those of tools described in L.23.1.10, that control the primary operating means of the tool shall have adequate breaking capacity. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Compliance is checked by subjecting a switch to 50 operations of making and breaking the locked output mechanism current of the fully charged battery-operated tool, each “on” period having a duration of not more than 0,5 s and each “off” period having a duration of at least 10 s. After this test the power switch shall have no electrical or mechanical failure. If the switch operates properly in the on and off positions at the end of the test, it is considered to have no mechanical or electrical failures. L.23.1.11 The subclause of the standard applies only to tools capable of performing their intended operation when connected to the mains or to a non-isolated source for those switches that control the primary operating means of the tool. L.23.1.11.201 Switches, other than those of tools described in L.23.1.11 that control the primary operating means of the tool, shall withstand, without excessive wear or other harmful effect, the mechanical, electrical, and thermal stresses occurring in normal use. Compliance is checked by subjecting a switch to 6 000 cycles of operation making and breaking the current encountered in the fully charged battery tool operated at no-load. The switch is operated at a uniform rate of 30 operations per minute. During the test the switch shall operate correctly. After the test, inspection of the switch shall show no undue wear, no discrepancy between the position of the operating means and that of the moving contacts, no loosening of electrical or mechanical connections, no seepage of sealing compound. L.24 Supply connection and external flexible cords L.24.1 This subclause also applies to a flexible cord between a non-isolated power source and the tool. L.24.3 This subclause also applies to a flexible cord between a non-isolated power source and the tool. L.24.4 This subclause applies, except a flexible cord provided between a non-isolated power source and the tool shall not be provided with a plug that can be connected directly to the mains. L.24.5 This subclause does not apply to a flexible cord provided between a non-isolated power source and the tool. L.24.21 This subclause applies, except a flexible cord provided between a non-isolated power source and the tool shall not be provided with an appliance inlet that can be connected directly to the mains. L.24.201 For battery tools with separable battery packs, the external flexible cable or cord shall have anchorages such that the conductors are relieved from strain, including twisting, where they are connected within the tool, and protected from abrasion. Compliance is checked by inspection. L.25 Terminals for external conductors This clause does not apply to interconnecting cords. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI L.26 Provision for earthing The clause of the standard is applicable except as follows: L.28.1 Addition: NOTE Figure L.1 provides clarification on the measurement method. Compliance is checked by measurement. Creepage Clearance Creepage distance EN 60745-1:2006 This clause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. L.28 Creepage distances, clearances and distances through insulation This subclause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. During the evaluation in this condition, battery packs are to be connected to the tool. The tool is also evaluated with the battery pack removed if such removal can be accomplished without the use of a tool. L.28.201 Creepage distances and clearances shall not be less than values in millimetres shown in Table L.1. The clearances specified do not apply to the air gap between the contacts of thermal controls, overload protection devices, switches of micro-gap construction, and the like, or to the air gap between the current-carrying members of such devices where the clearances vary with the movement of the contacts. Creepages and clearances also do not apply to the construction of battery cells or the interconnections between cells in a battery pack. The values specified in Table L.1 do not apply to cross-over points of motor windings. For parts having a hazardous voltage between them, the sum total of the measured distances between each of these parts and their nearest accessible surface shall not be less than 1,5 mm clearance and 2,0 mm creepage. The way in which creepage distances and clearances are measured is indicated in Annex A. For parts of different polarity, clearance and creepage distances less than those given in Table L.1 are acceptable if the shorting of the two parts does not result in the tool starting. NOTE The risk of fire due to spacings below the required values is covered by the requirements of 18.1. Table L.1 – Minimum creepage distances and clearances between parts of opposite polarity Dimensions in millimetres ≤15 V >15 V and ≤32 V >32 V Clearance Creepage Clearance distance distance – 0,8 – 1,5 2,0 1,5 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Distances through slots or openings in external parts of insulating material are measured to metal foil in contact with the accessible surface; the foil is pushed into corners and the like by means of the standard test finger of Figure 1, but is not pressed into openings. The sum total of distances measured between parts operating at hazardous voltage and accessible surfaces is determined by measuring the distance from each part to the accessible surface. The distances are to be added together to determine the sum total. See Figure L.1. For the purpose of this determination, one of the distances shall be 1,0 mm or greater. See Annex A, cases 1 to 10. If necessary, a force is applied to any point on bare conductors and to the outside of metal enclosures, in an endeavour to reduce the creepage distances and clearances while taking the measurements. The force is applied by means of a test finger having a tip as shown in Figure 1 and has a value of: – 2 N for bare conductors; – 30 N for enclosures. If a barrier is interposed, and if it is in two parts which are not cemented together, the creepage distance is also measured through the joint. If a barrier is interposed, clearances are measured over the barrier or, if the barrier is in two parts with mating surfaces which are not cemented together, through the joint. When assessing creepage distances and clearances, the effect of insulating lining of metal enclosures or covers is taken into consideration. Means provided for fixing the tool to a support are considered to be accessible. L.29 Resistance to heat, fire and tracking The clause of the standard is applicable except as follows: L.29.1 Addition: This subclause only applies when the tool is in the configuration where it is directly connected to the mains or to a non-isolated source. In the case of tools that can charge the battery while performing their intended function, the battery pack shall be evaluated with the charger connected to the mains and with a battery in a condition that results in the most unfavourable temperatures. In addition, tools capable of charging the battery and which may also be capable of performing its intended operation shall also be evaluated with battery power alone if this may create temperatures that are more unfavourable. For the purposes of this clause, a part that is energized only by a battery source is not to be considered live. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI a + b is the sum total as defined in L.28.201. a b IEC 535/06 Dimension a = distance from positive bare conductive part to the external surface as defined by foil stretched across the openings. Dimension b = distance from negative bare conductive part to the external surface as defined by foil stretched across the openings. Figure L.1 – Measurement of clearances Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex M (normative) Safety of working stands for operation with hand-held motor-operated electric tools M.1 Scope This annex applies to working stands with and without mains supply, and intended to be used in combination with hand-held electric tools but not intended for continuous production or production line use. All clauses of this standard apply as far as reasonable for the type of working stand, unless otherwise specified in this annex. For the purpose of this annex, the term “tool” as it appears in the main body of this standard is understood to refer to the working stand. M.2 Normative references This clause is applicable except as follows: Additional normative reference: IEC 60204-1, Safety of machinery – Electrical equipment of machines – Part 1: General requirements M.3 Terms and definitions This clause is applicable except as follows: M.3.201 working stand device that a hand held electric motor operated tool is attached to in order to operate as a stationary electric motor-operated tool. Some working stands integrate clamping devices, protective equipment and supports for accessories (saw blades, bits and the like) M.3.202 adjusting/control device device used to adjust/control a function of the working stand or tool M.3.203 dust collection equipment device intended to remove and collect dust and chips, either integral or with optional connection to an external suction equipment Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI M.5 General conditions for the tests This clause is applicable except as follows: M.5.201 If the test results for the working stand, under any clause of this standard, are dependent on the tool used on the working stand, then the tool / working stand combination stated in M.8.12.2 a) 201) that leads to the most unfavourable results shall be tested. For the tool / working stand combinations stated in M.8.12.2.a) 201), the working stand shall not adversely affect the safety of the tool when used in combination with such. M.7 Classification This clause is applicable except as follows: M.7.1 Replacement: If the working stand is designed for - Class I tools or - Class I and Class II tools, parts of the electrical system supplying the tool shall be of Class I. If the working stand is designed for Class II tools, parts of the electrical system supplying the tool shall be of Class I or Class II. Compliance is checked by inspection and by the relevant tests. M.8 Marking and instructions This clause is applicable except as follows: M.8.1 Addition: The working stand shall be marked with capacities, such as power, weight, dimensions, as specified in the relevant part 2. M.8.12.1.1 Replacement: General Working Stand Safety Warnings WARNING Read all safety warnings and all instructions provided with the working stand and the power tool to be mounted. Failure to follow the warnings and instructions may result in electric shock, fire and/or serious injury. Save all warnings and instructions for future reference. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI The term "power tool" in the warnings refers to your mains-operated (corded) power tool or battery-operated (cordless) power tool. NOTE The terms “working stand” and “power tool” may be substituted by a specific name, i.e. “router table” and “router”. Disconnect the plug from the power source and/or the battery pack from the power tool before making any adjustments or changing accessories. Accidental starting of the power tool is a cause of some accidents. Properly assemble the working stand before mounting the tool. Proper assembly is important to prevent risk of collapse. Securely fasten the power tool to the working stand before use. Power tool shifting on the working stand can cause loss of control. Place the working stand on a solid, flat and level surface. When the working stand can shift or rock, the power tool or workpiece cannot be steadily and safely controlled. Do not overload the working stand or use as ladder or scaffolding. Overloading or standing on the working stand causes the stand to be “top-heavy” and likely to tip over. NOTE The above warning may be omitted if the working stand is unlikely to be used as ladder or scaffolding, e.g. because it is too small. M.8.12.2 a) Addition: 201) Information about the electric tools intended to be installed in the working stand and a warning to hazards if an electric tool is installed which is not intended for use with this working stand. 202) If applicable, the instruction manual shall provide information on how to assemble and secure the stand to the floor, bench, etc. M.10 Starting This clause is not applicable. M.11 Input and current This clause is not applicable. M.17 Endurance This clause is applicable except as follows: M.17.2 Replacement of the fifth paragraph: The test is performed in the normal operating position of the working stand. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI M.19 Mechanical hazards This clause is applicable except as follows: M.19.201 Working stands which may be used without fixing to the floor or to a table shall have adequate stability. Compliance is checked by the following test: Working stands with an appliance inlet are fitted with an appropriate connector and a flexible cable or cord. The working stand fitted with the electric tool is placed with the electric tool switched off in any normal position of use on a plane inclined at an angle of 10° to the horizontal, the cable or cord resting on the inclined plane in the most unfavourable position. If, however, the working stand s such that, were it to be tilted through an angle of 10° when standing on a horizontal plane, a part of the working stand normally not in contact with the supporting surface would touch the horizontal plane, the working stand is placed on a horizontal plane and tilted in the most unfavourable direction through an angle of 10°. Working stands with doors are tested with the doors open or closed whichever is the most unfavourable. Working stands intended to be filled with liquid by the user in normal use are tested empty or filled with the most unfavourable quantity of water or the recommended liquid, up to the rated capacity. The working stand shall not overturn. M.19.202 Screws which make a mechanical connection between different parts of the working stand shall not become loose in normal use. Compliance is checked by inspection. M.19.203 Any protective devices such as guards, which are necessary for the combination of the working stand and the tool shall be delivered with the working stand. It is stated in the relevant part 2 which protective devices are required to be delivered with the working stand. Compliance is checked by inspection. M.19.204 Use of a tool with a stand shall not impair the safety of the hand-held tool when removed from the stand and used as a stand-alone product. Compliance is checked by inspection. M.21 Construction This clause is applicable except as follows: Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI M.21.17 Replacement: Switches shall be so located that accidental operation is unlikely to occur. Compliance is checked by applying a sphere with a diameter of 100 mm ± 1 mm to the switch. It shall not be possible to start the electric tool by means of the sphere. M.21.18 Replacement: The mains switch of the working stand or of the hand-held motor-operated electric tools shall be so located that it can be switched on and off by the user from the operator’s position. When a switch has a locking arrangement to lock it in the “on” position, the requirement in M.21.18 is considered as being met provided the switch unlocks automatically when the trigger or actuating member is actuated. It is stated in the relevant part 2, whether a working stand shall be fitted with a switch to start and stop the installed electric tool. Compliance is checked by inspection and by manual test. M.21.201 A handle, a lever, a knob, or other control that is likely to be actuated while the tool is in operation shall be so located that, from the operator’s position, it is not necessary to traverse an area that may involve a risk of injury when reaching for it. If an area that may involve a risk of injury is adjacent to the control then this area shall be guarded or so located that it cannot be entered unintentionally. Compliance is checked by inspection. M.21.202 Working stands shall be equipped with facilities needed to fix the hand-held electric tools which are intended to be installed. Compliance is checked by inspection. M.21.203 After voltage recovery, following an interruption of the power supply, the reactivation of the electric tool/working stand shall not cause a hazard. The relevant part 2 shall state if this clause is applicable. Compliance is checked by inspection. M.21.204 If the tool is provided with a dust collection system, the working stand shall be designed such that in normal use the dust-collection devices on the tool can be used without any restriction. Alternatively the working stand itself may be fitted with dust-collection devices, either integral or to be connected to external dust collection equipment, that performs in an equivalent manner. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI If additional measures are necessary for dust collection, this is stated in the relevant part 2. Compliance is checked by inspection and by manual test. M.23 Components This clause is applicable except as follows: M.23.1.10 Replacement: Mains switches shall be rated for at least the tool with the highest rated input or rated current recommended by the manufacturer and shall be rated for 10 000 cycles of operation. Compliance is checked by inspection and by the following test which shall be performed with the hand-held motor-operated electric tool that has the highest rated input or rated current recommended by the manufacturer. The mains switch of the working stand is tested at rated voltage or at the upper limit of the rated voltage range of the tool. The motor is then stalled, and the switch is operated 50 times, each "on" period being not more than 0,5 s, and each "off" period being not less than 10 s. If, in normal use, an electronic control device switches off the current before opening the main contacts, the number of operations is reduced to five, with the electronic control device short-circuited. After the test, the switch shall have no electrical or mechanical failure. Mains switches marked with individual ratings are also tested in accordance with IEC 61058-1. M.23.1.11 Replacement: Switches which have not been separately tested and found to comply with IEC 61058-1 under the conditions occurring in the tool shall comply with Annex I. The test of 17.2.4.4 of IEC 61058-1 is carried out for 10 000 cycles of operation. Switches intended for operation under no-load, and which can be operated only with the aid of a tool, are subjected to the tests of Clause 17 of IEC 61058-1. This applies also to such switches operated by hand which are interlocked so that they cannot be operated under load, but switches without that interlock are subjected to the test of 17.2.4.4 for 100 cycles of operation. The tests of 17.2.4.4 of IEC 61058-1 are not carried out on a switch if the working stand meets the requirements of this standard when the switch is short-circuited. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI M.24 Supply connection and external flexible cords This clause is applicable except as follows: M.24.12 This subclause in not applicable. M.25 Terminals for external conductors This clause is applicable except as follows: M.25.201 Terminals shall comply with IEC 60204-1. Compliance is checked by inspection. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI N.1 General N.2 Correct operation test N.3 Electric strength test b) inaccessible metal parts. EN 60745-1:2006 Annex N (informative) Rules for routine tests The tests specified in this annex are intended to reveal, as far as safety is concerned, unacceptable variations in material or manufacture. These production tests do not impair the properties and the reliability of the tool, and should be made by the manufacturer on each tool. In general, more tests, such as repetition of type tests and sampling tests, have to be made by the manufacturer to ensure that every tool conforms with the samples that withstood the tests of this specification, according to the experience gained by the manufacturer. The manufacturer may use a test procedure which is better suited to his production arrangements and may make the tests at an appropriate stage during production provided it can be shown that tools which withstand the tests carried out by the manufacturer provide at least the same degree of safety as tools which the tests specified in this annex. the functional devices, such as switches and manually-operated controls, and by verifying the direction of rotation of motors. The insulation of the tools shall be checked by the following test: A voltage of substantially sine-wave form, having a frequency of 50 Hz or 60 Hz and the value shown in Table N.1, is immediately applied, for 3 s, between live parts and: a) accessible metal parts which may become live in the event of an insulation fault or as a result of incorrect assembly; The tests of item a) are made on the assembled tool; the test of item b) is made on the tool, either completely assembled, or in the production line. The tests of item a) are made on all tools, the tests of item b) being only made on class II tools. The high-voltage transformer used for the tests shall be so designed that, when the output terminals are short-circuited after the output voltage has been adjusted to the appropriate test voltage, the output current is at least 200 mA. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI The overcurrent relay shall trip when the output current exceeds 5 mA. No flashover or breakdown shall occur during the tests. Over basic insulation Over double insulation or reinforced insulation N.4 Earthing continuity test EN 60745-1:2006 Care shall be taken that the r.m.s. value of the test voltage applied is measured within ± 3 % and that the voltage measuring device or other indicator responds to the output voltage of the transformer. Attention is drawn to the fact that the test described cannot always be used if the tool incorporates d.c. components; in such cases, tests with d.c. may be necessary. The inherent resistance of the d.c. source shall allow a short-circuit current of at least 200 mA. Table N.1 – Test voltages for the electric strength test Application of test voltage Test voltage V Class III tools Class II tools Class I tools 1 000 1 000 - 2 500 - For class I tools, a current of at least 10 A, derived from an a.c. source having a no-load voltage not exceeding 12 V, is passed between the earthing terminal or the earthing contact and, in turn, each of the accessible metal parts which need to be earthed for safety reasons. The voltage drop between the earthing contact of the plug or the external end of an earth continuity conductor or of the appliance inlet and the accessible metal part is measured, and the resistance calculated from the current and this voltage drop. In no case shall the resistance exceed 0,3 Ω. This value is applicable to supply cable lengths up to 5 m. In case of supply cables having a length exceeding 5 m, it is increased by 0,12 Ω for any further length of 5 m. Care shall be taken that the contact resistance between the tip of the measuring probe and the metal parts under test does not influence the test results. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Bibliography IEC 60335-2-29, Household and similar electrical appliances – Safety – Part 2: Particular requirements for battery chargers IEC 60335-2-45, Household and similar electrical appliances – Safety – Part 2: Particular requirements for portable heating tools and similar appliances IEC 60601 (all parts), Medical electrical equipment IEC 61000-3-2, Electromagnetic compatibility (EMC) – Part 3-2: Limits – Limits for harmonic current emissions (equipment input current ≤16 A per phase) IEC 61000-3-3, Electromagnetic compatibility (EMC) – Part 3: Limits – Section 3: Limitation of voltage fluctuations and flicker in low-voltage supply systems for equipment with rated current ≤16 A CISPR 11, Industrial, scientific and medical (ISM) radio-frequency equipment – Electro- magnetic disturbance characteristics – Limits and methods of measurement CISPR 14-1, Electromagnetic compatibility – Requirements for household appliances, electric tools and similar apparatus – Part 1: Emission CISPR 14-2, Electromagnetic compatibility – Requirements for household appliances, electric tools and similar apparatus – Part 2: Immunity – Product family standard ___________ Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI IEC 60065 (mod) Audio, video and similar electronic apparatus - Safety requirements IEC 60127-3 -1) Miniature fuses Part 3: Sub-miniature fuse-links industrial purposes general purposes Household and similar electrical appliances - Safety Part 1: General requirements _________ EN 60745-1:2006 Annex ZA (normative) Normative references to international publications with their corresponding European publications The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies. NOTE When an international publication has been modified by common modifications, indicated by (mod), the relevant EN/HD applies. Publication Year Title EN/HD Year IEC 60061 Data- base EN 60061 Series Lamp caps and holders together with gauges for the control of interchangeability and safety EN 60065 + corr. March IEC 60068-2-75 Environmental testing Part 2-75: Tests - Test Eh: Hammer tests EN 60068-2-75 IEC 60085 -F1) Electrical insulation - Thermal classification EN 60085 2004F2) IEC 60112 Method for the determination of the proof and the comparative tracking indices of solid insulating materials EN 60112 19962) EN 60127-3 + corr. June IEC 60227F3) (mod) Series Polyvinyl chloride insulated cables of rated IEC 60245F4) (mod) voltages up to and including 450/750 V Series Rubber insulated cables - Rated voltages up IEC 60309 (mod) to and including 450/750 V Series Plugs, socket-outlets and couplers for EN 60309 Series IEC 60320 Series Appliance couplers for household and similar EN 60320 Series IEC 60335-1 (mod) A1 IEC 60384-14 -1) Fixed capacitors for use in electronic equipment Part 14: Sectional specification - Fixed capacitors for electromagnetic interference suppression and connection to the supply mains EN 60335-1 A1 A11 A12 + corr. July EN 60384-14 20052) 1) Undated reference. 2) Valid edition at date of issue. 3) The HD 21 series, which is related to, but not directly equivalent with the IEC 60227 series, applies instead. 4) The HD 22 series, which is related to, but not directly equivalent with the IEC 60245 series, applies instead. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI IEC 60695-11-5 Fire hazard testing Part 11-5: Test flames - Needle-flame test method - Apparatus, confirmatory test arrangement and guidance IEC 60695-11-10 -1) Fire hazard testing Part 11-10: Test flames - 50 W horizontal and vertical flame test methods IEC 60730-1 (mod) A1 (mod) -1) similar purposes IEC 60998-2-2 (mod) IEC 60999-1 Connecting devices - Electrical copper conductors - Safety requirements for screw- type and screwless-type clamping units Part 1: General requirements and particular requirements for clamping units for conductors from 0,2 mm² up to 35 mm² (included) IEC 61058-1 (mod) + A1 Switches for appliances Part 1: General requirements _________ 5) To be published. EN 60745-1:2006 Publication Year Title EN/HD Year IEC 60417 Data- base Graphical symbols for use on equipment - - IEC 60529 A1 IEC 60695-2-11 -1) Fire hazard testing Part 2-11: Glowing/hot-wire based test methods - Glow-wire flammability test method for end-products Degrees of protection provided by enclosures (IP Code) EN 60529 + corr. May A1 EN 60695-2-11 20012) EN 60695-11-5 EN 60695-11-10 19992) 200XF5) IEC 60760 -1) Flat, quick-connect terminations - - IEC 60825-1 EN 60730-1 A1 A11 A12 A13 A14 A15 Automatic electrical controls for household and similar use Part 1: General requirements 19942) EN 60825-1 + corr. February + A11 Safety of laser products Part 1: Equipment classification, requirements and user's guide IEC 60884 Series Plugs and socket-outlets for household and - - IEC 60998-2-1 (mod) -1) Connecting devices for low-voltage circuits for household and similar purposes Part 2-1: Particular requirements for connecting devices as separate entities with screw-type clamping units EN 60998-2-1 20042) -1) Connecting devices for low-voltage circuits for household and similar purposes Part 2-2: Particular requirements for connecting devices as separate entities with screwless-type clamping units EN 60998-2-2 20042) EN 60999-1 EN 61058-1 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI ISO 1463 -1) Metallic and oxide coatings - Measurement of coating thickness - Microscopical method ISO 3744 Acoustics - Determination of sound power levels of noise sources using sound pressure - Engineering method in an essentially free field over a reflecting plane ISO 3864-2 -1) Graphical symbols - Safety colours and safety signs Part 2: Design principles for product safety labels ISO 4871 Acoustics - Declaration and verification of noise emission values of machinery and equipment ISO 5347 Series Methods for the calibration of vibration and shock pick-ups ISO 7010 -1) Graphical symbols - Safety signs in workplaces and public areas ISO 8041 Human response to vibration - Measuring instrumentation ISO 11203 Acoustics - Noise emitted by machinery and equipment - Determination of emission sound pressure levels at a work station and at other specified positions from the sound power level EN 60745-1:2006 Publication Year Title EN/HD Year IEC 61540 (mod) + A1 (mod) HD 639 S1 + corr. July + A1 Electrical accessories - Portable residual current devices without integral overcurrent protection for household and similar use (PRCDs) IEC 61558-1 -1) Safety of power transformers, power supplies, reactors and similar products Part 1: General requirements and tests 20052) EN 61558-1 + corr. August - - Mechanical vibration - Declaration and verification of vibration emission values EN 12096 CR 1030-1 Hand-arm vibration - Guidelines for vibration hazards reduction Part 1: Engineering methods by design of machinery - - EN ISO 1463 20042) ISO 2178 -1) Non-magnetic coatings on magnetic substrates - Measurement of coating thickness - Magnetic method EN ISO 2178 19952) EN ISO 3744 - - EN ISO 4871 - - ISO 5349 Series Mechanical vibration - Measurement and EN ISO 5349 Series evaluation of human exposure to hand-transmitted vibration - - ISO 7574-4 Acoustics - Statistical methods for determining and verifying stated noise emission values of machinery and equipment Part 4: Methods for stated values fro batches of machines EN 27574-4 EN ISO 8041 ISO 9772 -1) Cellular plastics - Determination of horizontal burning characteristics of small specimens subjected to a small flame - - EN ISO 11203  Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI ISO/TR 11690-3 Acoustics - Recommended practice for the design of low noise workplaces containing machinery Part 3: Sound propagation and noise prediction in workrooms ISO 16063-1 Methods for the calibration of vibration and shock transducers Part 1: Basic concepts ISO 20643 Mechanical vibration - Hand-held and hand-guided machinery Principles for evaluation of vibration emission EN 60745-1:2006 Publication Year Title EN/HD Year ISO/TR 11688-1 Acoustics - Recommended practice for the design of low noise machinery and equipment Part 1: Planning EN ISO 11688-1 EN ISO 11690-3 - - EN ISO 20643  Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI Annex ZB (informative) Possible sources of errors during vibration measurements This annex does not constitute an exhaustive list of possible sources of errors. It should only be considered as a guide to avoid the main errors in measurement: a) unsuitable mounting or fastening of transducers; b) inadequate fastening of cables; c) lack or misadjustment of band-pass filter; d) not nulling output of amplifiers after mounting of transducers; e) misalignment of directions of transducers or inappropriate or varying position of the transducers; f) inappropriate signal conditioning (band-pass, signal-to-noise ratio, overload, etc.); g) too short duration of measurement; h) lack of calibration before and after measurement; i) inappropriate definition of operational conditions; j) inexperienced operators using inappropriate grip forces; k) unstable operating conditions, such as fluctuating feed forces and varying motor speed. Further practical advice on measurement errors is given in EN ISO 5349-2. Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI blank BS EN 60745-1:2006 Licensed Copy: Institute Of Technology Tallaght, Institute of Technology, Sat Mar 17 19:46:14 GMT+00:00 2007, Uncontrolled Copy, (c) BSI BSI 389 Chiswick High Road London W4 4AL BSI — British Standards Institution BSI is the independent national body responsible for preparing British Standards. It presents the UK view on standards in Europe and at the international level. It is incorporated by Royal Charter. Revisions British Standards are updated by amendment or revision. Users of British Standards should make sure that they possess the latest amendments or editions. It is the constant aim of BSI to improve the quality of our products and services. 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