What Makes a Tool EN 60900 Compliant?
EN 60900 (equivalent to IEC 60900) specifies the design, insulation material, voltage withstand tests and marking requirements for insulated hand tools. A compliant tool must:
- Withstand a dielectric test at 10,000 V AC for 3 minutes during production testing
- Provide working insulation rated at 1,000 V AC / 1,500 V DC
- Bear the permanent double-triangle symbol with the "1000V" voltage rating
- Carry a VDE, GS or equivalent certification mark from an accredited body
- Have insulation that covers the entire handle to within 10 mm of the working end
When Are Insulated Tools Required for HV Work?
EN 60900 tools are required in any situation where there is a risk of inadvertent contact with active HV components. This includes:
- Any work in the HV system area of a vehicle, even if the vehicle is de-energised (as a precautionary measure)
- All work near open HV connectors, exposed HV cables or HV junction boxes
- Any live HV work (Level 3S/3E) – the tool insulation is the last line of defence
- Work on HV charging infrastructure and stationary HV systems
Standard tools – even those with rubberised handles – provide no meaningful protection and must not be used as a substitute for EN 60900 certified tools.
Inspection and Maintenance
- Visual check before each use – inspect for cracks, cuts, swelling, discolouration or delamination of the insulation
- Annual electrical testing – under DGUV Vorschrift 3 and BetrSichV §14, insulated tools must be periodically tested; many organisations test annually
- Any tool with damaged insulation must be removed from service immediately – it cannot be repaired and continued in use
- Store separately from standard tools to prevent accidental substitution
- Keep a register of VDE tools with inspection dates and results
Can the same EN 60900 tools be used for both HV vehicle work and general electrical work?
Yes, EN 60900 tools are suitable for any electrical work up to 1,000 V AC. However, tools that are used for general workshop work may suffer abrasion and damage to the insulation more rapidly. It is best practice to keep a dedicated set of VDE tools for HV vehicle use and inspect them more frequently. Label them clearly and store them separately.
Is the VDE mark on its own enough to confirm EN 60900 compliance?
The VDE mark alone indicates the tool has been tested by VDE, but not necessarily to EN 60900. Always check that the tool also bears the double-triangle voltage symbol with "1000V" marking. These two together confirm EN 60900 compliance. If only one is present, the tool's voltage rating may be lower than required for HV vehicle work.
Correct Tool Selection is Covered in All HV Courses
PPE requirements including EN 60900 tool selection are trained hands-on in every Hochvolt-Experten course. Nationwide in-house training.
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