IEC 60079-35-2:2011

Explosive atmospheres - Part 35-2: Caplights for use in mines susceptible to firedamp - Performance and other safety-related matters

IEC 60079-35-2:2011 details those performance and other safety features of caplights, including those with a point of connection for another equipment, not covered in IEC 60079-35-1, but which are important for the safety and working conditions of the user. It may also be applied to caplights for use in mines not likely to be endangered by firedamp. This first edition of IEC 60079-35-2 cancels and replaces the second edition (2005) of IEC 62013-2 published in 2005 and constitutes a full technical revision. The general revision and updating of Edition 2 of IEC 62013-2 has been necessitated by the advent of new technologies related to caplight design, in particular those related light-emitting diode (LED) light sources. It is intended that there should be a stronger link between Part 1 (Construction) and Part 2 (Performance) of this Standard by upgrading the reference in the Scope of part 1 from a note to a requirement. In addition as this Standard is now to become one of the IEC 60079 series, changes have been made to bring it more in line with others in the series by cross referencing. This has enabled there to be a reduction in the number and length of clauses in the Standard.

Atmosphères explosives - Partie 35-2: Lampes chapeaux utilisables dans les mines grisouteuses - Performances et autres sujets relatifs à la sécurité

La CEI 60079-35-2:2011 détaille les performances et les autres caractéristiques de sécurité des lampes-chapeaux, y compris de celles ayant un point de connexion pour un autre appareil, qui ne sont pas couvertes par la CEI 60079-35-1, mais qui sont importantes pour la sécurité et les conditions de travail de l'utilisateur. Elle peut aussi s'appliquer aux lampes-chapeaux utilisées dans les mines non grisouteuses. La présente première édition de la CEI 60079-35-2 annule et remplace la deuxième édition (2005) de la CEI 62013-2 publiée en 2005 dont elle constitue une révision technique complète. La révision générale et la mise à jour de l'édition 2 de la CEI 62013-2 sont devenues indispensables avec l'avènement des nouvelles technologies touchant la conception des lampes chapeaux, en particulier celles liées aux sources de lumière à diodes électroluminescentes (LED). Il est prévu de lier plus fortement la Partie 1 (Construction) et la Partie 2 (Performance) de la présente norme en modifiant le contenu du domaine d'application de la partie 1 de note en exigence. En outre, la présente norme ayant été intégrée à la série CEI 60079, des modifications ont été apportées dans un souci de plus grande cohérence avec les autres parties de la série par l'ajout de références croisées. Ceci a permis une réduction à la fois du nombre et de la longueur des articles de la présente norme.

General Information

• Status: Published
• Publication Date: 06-Dec-2011
• ICS: 29.260.20 - Electrical apparatus for explosive atmospheres
• Technical Committee: TC 31 - Equipment for explosive atmospheres
• Drafting Committee: MT 60079-35 - TC 31/MT 60079-35
• Current Stage: PPUB - Publication issued
• Start Date: 07-Dec-2011
• Completion Date: 15-Jan-2012

Relations

• Replaces: IEC 62013-2:2005 - Caplights for use in mines susceptible to firedamp - Part 2: Performance and other safety-related matters
• Effective Date: 05-Sep-2023

Overview

IEC 60079-35-2:2011 is an international standard published by the International Electrotechnical Commission (IEC) that specifies performance and safety requirements for caplights used in mines susceptible to firedamp. Firedamp, a hazardous explosive atmosphere primarily composed of methane, presents significant safety risks in mining environments. This standard addresses performance features not covered in its companion document IEC 60079-35-1, particularly focusing on light output, reliability, ergonomics, and user safety to enhance working conditions for miners.

This edition, published in 2011, is a full technical revision replacing the earlier IEC 62013-2 (2005). It incorporates advancements in caplight technologies such as LED light sources and improves linkage with Part 1 of the standard by making cross-referencing mandatory. The update aligns this standard with the broader IEC 60079 series addressing equipment for explosive atmospheres.

Key Topics

Light Output Requirements

• Multiple Light Sources: Caplights must have at least two light sources, with one designated as the main source meeting performance criteria. A single non-filament source is permitted if it satisfies lamp life requirements.
• Beam Orientation: The caplight’s main beam must point downward at 10° ± 5° to optimize miner visibility without glare.
• Illumination Intensity: The standard requires a minimum luminous intensity cone of 1 cd (lux at 1 m) throughout the useful working period, with a maximum intensity minimum of 1,500 cd.
• Focus: The main light source must produce a focused light pattern free of distortion.
• Chromaticity: For LED or other non-filament light sources, the correlated color temperature (CCT) should be above 5,000 K with a color rendering index (CRI) greater than 70, unless otherwise specified.

Reliability and Durability

• Lamp and Battery Life: Specifies minimum lamp life for filament sources and battery charge/discharge cycles. Manufacturers must define the caplight’s useful working period based on current draw and luminous intensity maintenance.
• Physical Durability: Components such as fasteners and connectors must resist abrasion and maintain operability after mechanical stress testing.
• Maintainability: Caplights must be easy to operate and maintain, with secure headpiece attachment to avoid accidental detachment underground.

Ergonomics and Safety

• Weight and Comfort: Mass of the caplight should be optimized for lasting comfort during extended underground use.
• Ease of Use: Controls and operational mechanisms are designed for straightforward use by miners wearing gloves or in wet conditions.
• Instructions and Marking: Clear manufacturer instructions and marking requirements ensure correct use, maintenance, and routine user testing.

Applications

IEC 60079-35-2:2011 is critical for manufacturers, designers, and users of caplights in mining environments where explosive atmospheres are present, specifically those susceptible to the presence of firedamp. These caplights provide safe, reliable, and effective lighting for miners, reducing the risk of ignition of explosive gases while improving visibility and safety in hazardous conditions. The standard also supports mining operations in non-gassy environments when safety agreements are reached between suppliers and users.

Industries and sectors benefitting from this standard include:

• Underground coal and mineral mining
• Safety equipment manufacturers specializing in mining lighting solutions
• Mining safety regulatory and compliance authorities
• Equipment testing and certification bodies

Related Standards

• IEC 60079-35-1: Caplights for use in mines susceptible to firedamp - General requirements covering construction and explosion risk testing.
• IEC 60983: Specifies requirements for miniature filament lamps used in caplights.
• IEC 60050-845: International Electrotechnical Vocabulary for lighting terms ensuring consistent terminology.
• ISO 80000-1: General quantities and units relevant for defining performance metrics.
• IEC 60079 Series: Broad suite of standards addressing equipment and protective systems within explosive atmospheres for varied industrial applications.

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Keywords: IEC 60079-35-2, caplights, mining safety equipment, explosive atmospheres, firedamp, LED caplight performance, mining illumination standards, caplight reliability, mining equipment ergonomics, IEC mining safety standards, underground mining lighting

Standards Content (Sample)

IEC 60079-35-2 ®
Edition 1.0 2011-12
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Explosive atmospheres –
Part 35–2: Caplights for use in mines susceptible to firedamp – Performance
and other safety-related matters

Atmosphères explosives –
Partie 35-2: Lampes chapeaux utilisables dans les mines grisouteuses –
Performances et autres sujets relatifs à la sécurité
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IEC 60079-35-2 ®
Edition 1.0 2011-12
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Explosive atmospheres –
Part 35–2: Caplights for use in mines susceptible to firedamp – Performance
and other safety-related matters

Atmosphères explosives –
Partie 35-2: Lampes chapeaux utilisables dans les mines grisouteuses –
Performances et autres sujets relatifs à la sécurité

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
PRICE CODE
INTERNATIONALE
M
CODE PRIX
ICS 29.260.20 ISBN 978-2-88912-818-1
– 2 – 60079-35-2 © IEC:2011
CONTENTS
FOREWORD . 3
1 Scope . 5
2 Normative references . 5
3 Terms and definitions . 5
4 Light output . 5
4.1 Light sources . 5
4.2 Light source holder . 6
4.3 Luminous intensity and illuminance . 6
4.4 Auxiliary light source . 6
4.5 Focus . 6
4.6 Chromaticity . 6
5 Reliability . 6
5.1 Lamp life . 6
5.2 Battery life (charge/discharge cycles) . 7
5.3 Caplight useful working period . 7
5.4 Durability . 7
5.4.1 Fasteners and connectors . 7
5.4.2 Resistance to abrasion . 7
5.4.3 Operability after mechanical tests . 7
6 Ergonomics . 7
6.1 Mass . 7
6.2 Ease of operation . 8
6.3 Maintainability . 8
6.4 Headpiece security . 8
7 Type tests – Illumination throughout the useful working period . 8
8 Instructions. 9
9 Marking . 9
Annex A (informative) Examples of the manufacturer’s instructions for routine testing
by the user. 10

Figure A.1 – Schematic drawing of a typical photometric sphere . 11

Table A.1 – Tabulation of tests . 12

60079-35-2 © IEC:2011 – 3 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
EXPLOSIVE ATMOSPHERES –
Part 35-2: Caplights for use in mines susceptible to firedamp –
Performance and other safety-related matters

FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
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Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested
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2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
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3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
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8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 60079-35-2 has been prepared by IEC technical committee 31:
Equipment for explosive atmospheres.
This first edition of IEC 60079-35-2 cancels and replaces the second edition (2005) of
IEC 62013-2 published in 2005 and constitutes a full technical revision.
The general revision and updating of Edition 2 of IEC 62013-2 has been necessitated by the
advent of new technologies related to caplight design, in particular those related light-emitting
diode (LED) light sources. It is intended that there should be a stronger link between Part 1
(Construction) and Part 2 (Performance) of this Standard by upgrading the reference in the
Scope of part 1 from a note to a requirement.
In addition as this Standard is now to become one of the IEC 60079 series, changes have
been made to bring it more in line with others in the series by cross referencing. This has
enabled there to be a reduction in the number and length of clauses in the Standard.

– 4 – 60079-35-2 © IEC:2011
The text of this standard is based on the following documents:
FDIS Report on voting
31/955/FDIS 31/963/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
A list of all the parts in the IEC 60079 series, under the general title Explosive atmospheres,
can be found on the IEC website.
The committee has decided that the contents of this publication will remain unchanged until
the stability date indicated on the IEC web site under "http://webstore.iec.ch" in the data
related to the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
60079-35-2 © IEC:2011 – 5 –
EXPLOSIVE ATMOSPHERES –
Part 35–2: Caplights for use in mines susceptible to firedamp –
Performance and other safety-related matters

1 Scope
This part of IEC 60079-35 details those performance and other safety features of caplights,
including those with a point of connection for another equipment, not covered in
IEC 60079-35-1, but which are important for the safety and working conditions of the user. It
may also be applied to caplights for use in mines not likely to be endangered by firedamp.
NOTE When this part of the standard is used as a "stand-alone" document for non-gassy mines, any relevant
constructional requirements should be the subject of agreement between the supplier and the user and, where
possible, be as described in IEC 60079-35-1.
2 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 60050-845, International Electrotechnical Vocabulary (IEV) – Chapter 845: Lighting
IEC 60983, Miniature lamps
IEC 60079-35-1, Explosive atmospheres – Part 35-1: Caplights for use in mines susceptible to
firedamp – General requirements – Construction and testing in relation to the risk of
explosion
ISO 80000-1, Quantities and units – Part 1: General
3 Terms and definitions
For the purposes of this document, the definitions of ISO 80000-1 and IEC 60050(845) and
the following apply:
3.1
useful working period
period in hours defined by the manufacturer, taking into account the current drawn by the
main light source and if appropriate, the average current drawn by any accessories during
that period, during which the main light source of the caplight may be continuously used and
comply with the minimum luminous intensity requirements of this standard
4 Light output
4.1 Light sources
4.1.1 Every headpiece shall have a minimum of two light sources, at least one of which shall
be the main source and meet the requirements of this part of IEC 60079-35. Alternatively a
___________
To be published
– 6 – 60079-35-2 © IEC:2011
single light source may be used provided it is a non-filament type and it meets the lamp life
defined in 5.1.
4.1.2 Where a caplight is fitted with two light sources, each of which is capable of being the
main source, the manufacturer shall designate which of these shall be the main source and
which the auxiliary source; otherwise, both sources shall meet the requirements for the main
source.
4.1.3 Filament lamps for main and auxiliary sources shall comply with IEC 60983. Where the
relevant data sheet is not given in IEC 60983, an equivalent shall be provided by the caplight
manufacturer.
4.2 Light source holder
The holder for the main light source shall be capable of locating and retaining it securely in a
focused position with respect to the reflector profile in accordance with 4.5.
4.3 Luminous intensity and illuminance
The main beam of light from a headpiece mounted on its intended helmet, in its normal
operating orientation, shall point 10 degrees ± 5 degrees down from the horizontal.
NOTE A statement from the caplight manufacturer stating compliance with this requirement is acceptable and
need not be verified if certification is sought.
At the end of the useful working period, the luminous intensity from the main light source in a
fully assembled headpiece, mounted on its intended helmet in its normal operating
orientation, shall extend a cone with a minimum of 1 cd (1 lux at 1m). This cone shall not be
less than 30 degrees up from the main beam of light, 60 degrees down from the main beam of
light and 60 degrees to each side. This may be calculated from manufacturers’ data or tested
in accordance with Clause 7. The maximum illumination shall not be less than 1 500 cd
(1 500 lux at 1 m).
4.4 Auxiliary light source
The auxiliary light source is primarily intended for emergency use if the main source fails and
is exempt from the type tests in Clause 7.
4.5 Focus
The main light source shall be focused, or capable of being focused, so that the light pattern
is not impaired by distortion.
4.6 Chromaticity
For non-filament light sources, the colour correlated temperature (CCT) shall be greater than
5 000 K and the colour rendering index (CRI) shall be greater than 70, unless alternative
values are specified by the caplight manufacturer and included in the user instructions.
NOTE The values of CCT and CRI supplied by the caplight manufacturer need not be verified if certification is
sought.
5 Reliability
5.1 Lamp life
The light source life of caplights fitted with two filament light sources shall comply with the
requirements of Lamps for miners’ caplights in IEC 60983. If the lamp manufacturer provides
a data sheet showing such test results, it may be accepted without further testing. The

60079-35-2 © IEC:2011 – 7 –
minimum life shall be not less than 200 h for the main source and 50 h for the auxiliary
source.
The light source life of caplights fitted with two non-filament light sources shall be not less
than 200 h for the main source and 50 h for the auxiliary source, when tested at the maximum
operating ambient temperature and nominal battery voltage.
For caplights with two light sources, after 200 hours the luminous intensity of the main light
source shall meet the requirements of 4.3.
The life of non-filament type single light sources shall not be less than 5 000 h when
determined either by test of the entire caplight headpiece or by using manufacturer's life data,
junction temperature, maximum operating ambient temperature, nominal battery voltage and
appropriate calculations based on the entire caplight headpiece. The resultant luminous
intensity after 5 000 hours source shall meet the requirements of 4.3.
5.2 Battery life (charge/discharge cycles)
It is not possible to specify a cyclic life for the battery due to the multiplicity of battery types,
charging regimes and conditions of use.
The manufacturer shall prepare instructions to the user on the recharge time and routine
checks which are necessary to ensure that the battery is capable of performing its intended
duties during the actual working period. See Clause 8 and Annex A.
NOTE The choice of battery charging equipment will depend on the time available between successive actual
working periods. When the recharge time is insufficient to fully recharge the battery, the manufacturer may need to
advise the user to provide additional caplights.
5.3 Caplight useful working period
The manufacturer shall declare the useful working period of the caplight when new, taking into
account the current drawn by the main light source and, if appropriate, the average current
drawn by any accessories during that period. The test requirements are given in Clause 7.
5.4 Durability
5.4.1 Fasteners and connectors
Fasteners and connectors shall be designed so that they are not likely to loosen in normal
use.
5.4.2 Resistance to abrasion
The caplight shall be constructed from materials which are resistant to abrasion in normal
use.
5.4.3 Operability after mechanical tests
Following completion of the Drop tests in IEC 60079-35-1, at least one light source shall still
be operable and there shall be no leakage of electrolyte.
6 Ergonomics
6.1 Mass
Unless otherwise agreed between the manufacturer and the user, the mass of the battery and
container shall not exceed 2 750 g and the total mass of the complete caplight assembly shall
not exceed 3 250 g.
– 8 – 60079-35-2 © IEC:2011
Unless otherwise agreed between the manufacturer and the user, the mass of headpiece only
caplights (caplights with an integral battery) shall not exceed 250 g. The recommended
maximum mass of the headpiece only caplight is 185 g.
6.2 Ease of operation
The switch shall be easily accessible to the wearer with the caplight in the position normally
worn. The switch shall be positive in action.
NOTE The switch should be operable while wearing protective gloves.
6.3 Maintainability
The caplight shall be constructed in such a manner that user replaceable parts are easily
accessible after operation or removal of any special fasteners.
If necessitated by the battery design, means shall be provided for initial filling, subsequent
topping up and changing of electrolyte.
6.4 Headpiece security
For caplights contained wholly on the helmet a tether that can be readily fastened to the
caplight and the torso shall be provided.
NOTE This tether should be durable, light and strong and also be designed to minimise the risk of the tether
being caught on mining infrastructure and equipment.
Where headpiece only caplights are intended for use on helmets that have restraints (chin
straps) this requirement does not apply.
7 Type tests – Illumination throughout the useful working period
The following test shall be carried out in a darkened room or enclosure having little or no
ambient airflow and where any reflected light will not influence the results, at a temperature of
(23 ± 2) °C.
Ensure that the caplight has a fully charged battery.
NOTE 1 It may be necessary to cycle the battery several times to achieve full capacity.
Switch on the main light source and, if appropriate, any additional device to simulate the
manufacturer’s declared total current drain.
Allow the caplight to operate for the useful working period.
Record the battery voltage.
NOTE 2 If an active device which affects the battery output is present, for example a switching regulator, the
voltage shall be measured at the input of such a device.
Disconnect the battery and connect the headpiece to a d.c. power source with a residual
ripple not greater than 3 mV and capable of maintaining the voltage within ± 0,01 V
throughout the test.
Adjust the power supply to the voltage measured at the end of the useful working period.
Focus the main light source of the headpiece.
Position the headpiece so that the protective cover is 1 000 mm ± 5 mm away from a
calibrated photometric cell.
60079-35-2 © IEC:2011 – 9 –
Move either the headpiece or photocell through the angles specified in 4.3 maintaining the

distance specified above. Record the reading on the photocell at 5 ° intervals, or in a specified
rectangular grid which gives the same result. The illumination shall meet the requirements of
4.3.
8 Instructions
The manufacturer shall prepare a comprehensive installation, operation, maintenance and
repair manual which includes at least the following:
a) information about the safe use of the caplight;
b) caplight useful working period;
c) the minimum illumination at the end of the useful working period at the angles defined in
4.3;
d) the minimum illumination at the end of the useful working period at the point of maximum
illumination.
e) permitted light source types;
f) periodic checks by the user to ensure continued safe use, maintenance and lighting
performance (see Annex A);
g) those parts which the user may replace;
h) list of special tools;
i) any special instructions required for disposal of batteries and any other applicable
components;
j) the colour correlated temperature (CCT) and the colour rendering index (CRI) of non-
filament light sources that do not meet the requirements of 4.6.
9 Marking
Caplights meeting the requirements of this part of IEC 60079-35 shall be marked with the
following information:
a) the name or trademark of the caplight manufacturer;
b) the manufacturer’s type identification;
c) the number of this standard (IEC 60079-35-2);
d) on the battery container or cells, a date or code to indicate the month and year of
manufacture.
NOTE Where the caplight also meets the requirements of IEC 60079-35-1, it is not necessary to repeat markings
required to appear by IEC 60079-35-1 that would otherwise be duplicated by the required markings of
IEC 60079-35-2.
– 10 – 60079-35-2 © IEC:2011
Annex A
(informative)
Examples of the manufacturer’s instructions
for routine testing by the user

NOTE Where national or local requirements apply, these should take precedence over the following.
A.1 Preparatory requirements
a) Select a representative sample of fully charged caplights from the charging racks so that,
during a period not exceeding four months, all caplights are tested;
b) Record the caplight identification or serial numbers;
c) Visually examine the caplights for defects that would impair performance or safety;
d) Repair any defects found or remove the caplight from service;
e) Clean the caplights according to the manufacturer’s instructions;
f) Switch on the main light source for a period of time equal to the length of the working shift
including any travelling time within the mine. If the caplight is to be used with an
accessory, the additional current will need to be taken into account when carrying out the
test.
A.2 Evaluation procedure
a) Example 1
Position the caplight headpiece 1 000 mm ± 5 mm from a suitably calibrated photocell.
Find the position of the highest measured value of illumination within a circle of diameter
100 mm ± 2 mm on a plane parallel to the headpiece protective cover and record the value
in lux (E ).
max
NOTE If the test is not carried out in a darkened room or if the photocell is not shielded against ambient
extraneous light, then a measurement should be made of this extraneous light before the test and the value
subtracted from the test result.
b) Example 2
Place the caplight headpiece at the window of an integrating sphere having the
dimensions shown in Figure A.1.
Measure the luminous flux in lumens.

60079-35-2 © IEC:2011 – 11 –
30° ± 1 % 30° ± 1 %
A
A
∅220 ± 2
28 ± 0,5
IEC  2582/11
Dimensions in millimetres
Key
1 Headpiece aperture
2 Photocell
3 Baffle
A Amplification of the baffle (viewed from direction of the arrow)
Figure A.1 – Schematic drawing of a typical photometric sphere
A.3 Pass requirement
a) Example 1
The maximum illumination at 1 m should not be less than 1 500 lx (lux).
b) Example 2
...