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Interpretation of the latest safety regulations for DC power tools in North America
Author.
LCS
Source:
Post time:
2025-07-21
With the advantages of strong adaptability, energy conservation and environmental protection, lithium battery electric tools have developed rapidly in recent years. High capacity and high-voltage lithium battery based tool products have been widely recognized in the market, including new products such as battery impact wrenches, hammers, chainsaws, lawn mowers, etc; The application scope of the product has also extended to industries mainly engaged in outdoor operations such as construction, transportation, landscaping, and shipbuilding.
Correspondingly, the market's entry threshold for lithium battery tools is also increasing year by year. As the strictest safety standard for battery products in history, UL 2595 General Requirements for Battery Products has emerged. The standard was absorbed into the national standards of the United States and Canada shortly after its birth, fully covering the requirements of UL 62841 Annex K. At the same time, it provides guiding assessment requirements for the use environment of the equipment. The certification process for battery powered garden tools, vacuum cleaners, and other products has already begun to require implementation.
In response to UL 2595 update,
What are the core concerns of manufacturers?
At present, the United States and Canada share the standard UL 2595/CSA C22.2 No.0.23, which is based on numerous standards such as IEC 60745-1 and IEC 62841-1. The product covers lithium-ion battery drive products below 75V, and under the new UL resolution requirements, it can be extended to battery type products below 250V.
UL 2595/CSA C22.2 No.0.23 is a universal standard for battery products and cannot be used alone for product certification. It is necessary to conduct safety assessments of the product in conjunction with specific final product standards, such as UL 82, UL 1447, UL 1090, UL 1017, etc.
Manufacturers need to focus on the following two points when updating this standard:
UL 2595 has improved the assessment of battery safety. Compared to previous standards for battery products (such as UL 745-3, UL 60745-1 Annex K, etc.), UL 2595 has further strengthened the quality requirements for battery products. Under the premise that the battery cells meet UL 62133/CSA E62133, UL 2595 has added assessments for charging and discharging unbalanced battery cells inside the battery pack. Under the premise of unbalanced preset power of some battery cells, different states (normal and abnormal) of charge and discharge tests are conducted on the battery pack to assess the safety of the battery pack.
Clarify the evaluation methods for the functional safety of DC lithium electric products. UL 2595 introduces the concept of functional safety and specifies the evaluation method for electronic circuits with protective functions, referencing ISO 13849-1. Namely: List the functional safety details that need to be evaluated in the annotation and indicate the standard safety level. These contents are the same as the requirements of UL 62841-1.
Which manufacturers need to pay special attention to the new standards,
And prepare for the next product upgrade?
Prior to the release of the UL/IEC 62841 series of garden tool standards, UL had already taken the lead by updating traditional garden tool standards (UL82, UL 1447, UL 1090, UL 1017, etc.) and adding consideration requirements for battery powered products using UL 2595. This is the first time that the market has clearly defined the standard requirements for battery powered garden tools. Manufacturers of battery powered garden tools are directly affected, and there is a risk of market rejection for battery powered garden tool products that do not meet UL 2595 requirements.
For handheld and desktop power tools, some UL 62841 standards have been released, and the old standards UL 60745 and UL 987 are still valid but have stopped updating. It is an inevitable trend for these products to meet UL 62841 requirements. The UL 62841 standard for some products has been released (see table below), and the products involved can be evaluated using the applicable standards in the table. For battery powered handheld power tools and desktop tools, UL 2595 covers the requirements of the new standard UL 62841 annex K. For manufacturers of such products, designing new products that meet UL 2595 will greatly shorten the upgrade process and be more conducive to seizing market opportunities.
What is the upgrade direction for DC lithium electric tools?
UL 2595/CSA C22.2 No.0.23 has the greatest impact on battery products, especially those with electronic protection. Firstly, manufacturers need to consider the protection design for unbalanced charging and discharging of battery cells when designing battery packs, in order to meet the technical requirements of the new standards. At the same time, the functional safety of the electronic circuit of the product needs to be checked through analysis and calculation to determine whether it meets the corresponding safety level PLr (given in the overall machine standard); Functional safety is achieved through software, and the software must undergo safety assessment in accordance with IEC 60730-1 H.11.12.3 to meet Class B requirements.
We suggest that manufacturers initiate early plans to upgrade their products to new standards, combine the updated standards with the products for analysis and research, optimize product design, and enhance the market competitiveness of the products. In addition, manufacturers can also cooperate with authoritative third-party testing institutions to learn more about changes in the front-end market, broaden their horizons and ideas, and occupy market advantages.
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