IP Codes

2

Introduction. 4

IP protection. 5

IP Codes. What do they mean? 5

Two numerals – a lot of information. 5

First code numeral. 6

Protection against the ingress of solid foreign bodies. 6

Second code numeral. 7

Protection against the ingress of water. 7

How is the testing done? 8

Protection against accidental contact and solid foreign bodies 8

Testing with a probe 8

Testing in a dust chamber 8

Protection against water 9

The water jet test 9

The submersion test 9

External testing confirms quality. 10

TÜV certification 10

What and how does the TÜV certify? 10

Direct information for users: the TUVdotCOM-ID 11

Instruments with extreme IP Codes: IP65 digital micrometer. 12

Quality inspection in production 13

Higher precision than the standard requires 13

Extreme shock resistance 14

Resistance against extreme temperatures 14

Extra large LCD display 15

Calibration Certificate included 15

Contents.

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IP66 Digital Caliper. 16

Innovative enclosure gaskets and encapsulations 16

IP67 Digital Caliper. 17

100% safety tests 18

Up to 1.7 years from just one battery 18

Calibration certificate supplied as standard 19

Digital Scales. 20

IP66 digital scale 20

List of tested cutting lubricants. 21

Inductive sensors and the ABSOLUTE system. 22

The reliable electromagnetic sensor 22

Patented worldwide: The ABSOLUTE System by Mitutoyo 23

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4

Introduction.

4

Measuring tools and instruments are subject to environmental influencesduring use. In many cases these af fect the function, life and reliability ofthe product. For example, digital calipers used for measuring componentsthat are being machined on a lathe are quite likely to be splashed withcutting lubricant, which then tends to penetrate the sensitive electronicsand degrade performance – or even render an instrument inoperable.Therefore, it is very important to design and constr uct tools andinstruments in such a way that they withstand such adverse influences andperform their function reliably over their design life.

In order for a potential user to be able to judge whether or not a tool is fitfor a particular purpose, there must be a way of defining the resistance ofthe electronic parts of a product to such influences in a consistent manner .

This is where IP Codes come in: an IP Code indicates the degr ee ofprotection for the electricalfunction of a piece ofequipment that is providedby its enclosure against theingress of solid objects, dustand water during use. Amanufacturer is entitled toapply a particular IP Code toequipment after testingproves that it is incompliance with theprotection requirements ofthat code.

This booklet explains the meaning of the various IP Codes as commonlyapplied to manual measuring tools and instruments.

Standard micrometers and calipers of the ‘old’ type withoutIP protection.

5

IP Codes. What do they mean?

Two numerals – a lot of information.

IP Codes are generally quoted in two-digit form (IP65, for example) asdefined in BS EN 60529 : 1992, Degrees of protection provided byenclosures (IP code). Additional and supplementary letters can beappended to an IP Code to indicate r esistance to other influences but theseare not relevant to us as far as small tools and instruments ar e concerned.

The first numeral of the code r efers to the degree of protection against theingress of solid foreign bodies and dust, and the second numeral specifiesprotection against the ingress of water. In general, the higher thenumerical value (first numeral 0 to 6, second numeral 0 to 8), the higher isthe degree of protection.

The table overleaf shows what the IP Codes mean. Note that this bookletuses the character ‘X’ to refer to code numerals that are not relevant to theexplanation. For example, ‘IPX5’ refers to a code whose second numeral is‘5’ but whose first numeral can be any one of those allowed.

IP protection.

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First code numeral. Protection against the ingress of solid foreign bodies.

0 UnprotectedThe ingress of solid foreign bodies is not

prevented through special protective measures.

1Protected againstlarge solid foreign

bodies

Protected against the ingress of solid foreign bodies more than

ø50 mm.

2Protected against

medium-sized solidforeign bodies

Protected against the ingress of solid foreign bodies more than

ø12.5 mm.

3Protected againstsmall solid foreign

bodies

Protected against the ingress of solid foreign bodies more than

ø2.5 mm.

4Protected againstgrain-shaped solid

foreign bodies

Protection against the ingress of solid foreign bodies more than

ø1 mm

5 Protected againstdust

The ingress of dust may not be completely pr evented but only to the extent that the operation and safety of the

instrument is not affected.

6 Dust-proof The ingress of dust is completely prevented.

6

First codenumeral

Degree of protection

Brief description Definition

7

Second code numeral. Protection against the ingress of water.

0 UnprotectedThe ingress of water is not prevented through

special protective measures.

1Protected againstdripping waterfalling vertically

Water drops falling vertically onto the instr ument may not haveany harmful effect.

2Protected againstdripping water

falling at an angle

Dripping water falling vertically may not have any harmful ef fecteven with the equipment tilted by

an angle of up to 15° from vertical.

3 Protected against spraying water

Water sprayed at an angle of up to 60° from vertical may not have any harmful ef fect.

4 Protected against splashing water

Water splashing against the enclosure from any direction mayhave no harmful effect.

5 Protected against water jets

A moderately strong water jet projected against the enclosurefrom any direction may have no harmful ef fect.

6Protected against

powerful water jets

A powerful water jet projected against the enclosure from anydirection may have no harmful effect.

7*Protected against

temporary submersion

If temporarily submersed under water at a depth of 1 metr e (referredto the lower edge of the enclosure), the quantity of water entering

the enclosure is small enough not to have any har mful effect.

8*Protected against

continuoussubmersion

The equipment is suited for continuous submersion under water .The conditions must be agreed between manufacturer and user

but must exceed the defaults of IPX7.

7

Second codenumeral

Degree of protection

Brief description Definition

* Does not imply protection from water jets

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Protection against accidental contact and solid for eign bodiesFor testing protection against contact and solid foreign bodies, two methods areused: a probe for the first code numerals 1 to 4, and a dust chamber for codenumerals 5 and 6.

Testing with a probeWhen testing is done using a pr obe, the latter – a rigid ball with a diameterbetween 12.5 and 50 mm or a rigid bar with deburr ed edges and a diameterbetween 2.5 and 1 mm (depending on the degr ee of protection) – is pressedagainst every opening of the instrument enclosure with a defined force. In this testthe full diameter of the probe may not pass into the interior of the enclosur ethrough one of these openings.

Testing in a dust chamberPowdered talc is kept in suspension by a dust-cir culating pump inside ahermetically sealed chamber. The powder must be fine enough to pass easilythrough a screen with defined mesh size installed in the chamber , and the quantityof powder in the chamber is specified.

The interior of theenclosure is kept belowthe pressure in the dustchamber (at atmospheric)using a vacuum pump.The defaults provided byIP5X or IP6X are fulfilled ifthere is no adverse effecton operation or no dustingress is detected.

How is the testing done?

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Protection against waterThe methods for testing the protection against water also become more and morecomplex the higher the code numeral. While the tests for IPX1 to IPX4 ar e still quitemoderate with water being dripped, sprayed or splashed on the enclosur e, codenumerals IPX5 and IPX6 demand a great deal more. There are two test methods: one isspraying by jet nozzle, the other by submersion in a water tank.

The water jet testThe jet water test for IPX5 and IPX6 dir ects a water jet from a nozzle against theenclosure from all possible directions. The diameter of the nozzle, the duration of the jetand the water flow rate are all defined. The minimum duration of the test is 3 minuteswhile the volume flow rate amounts to 12.5 or 100 litr es per minute.

The submersion testThe submersion test for IPX7 requires fullsubmersion in water for 30 minutes. Forthis test, the instrument tested must bepositioned in a way that simulates typicaloperating situations. The submersion depthis also defined. For instance, the lowestpoint of the display casing on a MitutoyoIP67 caliper must be located one metrebelow the water surface during the test.

Protection against water IPX5 test Protection against water IPX6 test

The test is carried out at 1 m depth for at least 30 minutes.

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TÜV certificationAs a forerunner in the development and production of manual measurementinstruments with extremely high IP-coded protection, Mitutoyo has its digitalmicrometers and calipers independently tested by the TÜV Rheinland Gr oup.

TÜV Rheinland confirms the high resistance indicated by the IP Codes Mitutoyoapplies to its measuring instruments by issuing appr opriate test certificatesfollowing long and intensive testing. For the user , this provides real assistance inthe purchasing decision because now there is independent verification of themanufacturer’s claims.

What and how does the TÜV cer tify?A certified product is one that has successfully passed tests (defined by the TÜVRheinland Group) such as, for instance, safety and quality tests. The TÜV issues acertificate confirming the tested product characteristics and states the individualnorms and standards according to which the tests were carried out.

First of all, the TÜV Rheinland Gr oup tests a representative specimen from thenormal production according to the relevant criteria. These tests are usuallyexecuted in the TÜV test laboratories.To ensure the certificate is not just a ‘snap-shot’, TÜV monitors and tests the r elated products at regular intervals. ForMitutoyo instruments, this means an annual sampling test at the TÜV in Cologne.In this way it is established that cer tified products continue to meet the definedrequirements.

External testing confirms quality.

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Direct information for users: the TUVdotCOM-IDThe TUVdotCOM-ID is the key to the cer tificates issued by the TÜV RheinlandGroup for tested and certificated products. Using this 10-digit code, thecertification of a product may be retrieved via the internet at any time. The ID hasonly to be entered in an input field on the TÜV homepage (www .tuv.com) and thecertification for the product immediately pops up for inspection.

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As the leading manufacturer of manual measurement instruments worldwide,Mitutoyo is particularly innovative in the field of IP pr otection. The introduction ofthe IP65 micrometer (and IP66/67 calipers) set new standar ds for protection ofdigital instruments against the harsh conditions of the workplace.

With the development of the IP65 digital micr ometer, Mitutoyo took a big stepforward concerning increased protection of electronic workshop tools. It is theworld’s first micrometer conforming to this protection standard – all otherconventional micrometers available so far only achieved an IP54 rating, at themost.

IP65 means that the new digital micr ometer is absolutely dustproof – and thusachieves the highest defined IP level with r espect to protection against accidentalcontact and solid foreign bodies. The second code numeral further certifies thatthe instrument is also protected against water jets – which means that itwithstands water jets projected against the enclosure from any direction withoutdamage. In this context it is r emarkable that the IP65 defaults are met withoutrestriction even with the data signal line connected.

Instruments with extreme IP Codes:IP65 Digital Micrometer.

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Another test is made on the electr onic system where, for example, the data outputand power consumption are checked.

Higher precision than the standard requiresNext to the IP classification, the digital micr ometer offers further top specs. Forinstance, it exceeds the 2 µm figure required by DIN 863 for measuringuncertainty.

Quality inspection in productionIn order to guarantee the reliability of the micrometer, various tests are carried outon all instruments on the production line. For instance, the IP pr otection test issimulated in a pressure chamberso that defective instruments aredetected immediately.

100% leak test on the production line

100% electrical test on the production line

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Resistance against extreme temperaturesThe IP65 micrometer also proves remarkably resistant against extremetemperatures and temperature fluctuations. To check this resistance, themicrometer was subjected to highly demanding ambient r oom temperature testsduring its development phase. These included 48-hour static tests underfluctuating room temperatures between 20 and 60°C and 95% humidity, and

240-hour endurance tests at –20and 60°C.

Extreme shock resistanceSpecial construction techniques applied to the enclosure confer extremely highshock resistance, which makes the instrument resilient even under tough operatingconditions. Drop tests from various heights were passed by the IP65 micrometerwithout problems. In these tests the instrument is dr opped in such a way that itstrikes a concrete floor from six different positions (side faces, handle, front, topand bottom surface), after which the tool must still be fully functional.

Climatic test during development

Construction improvementsinside the device

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Calibration certificate includedIP65 digital micrometers, up to 50 mm, are supplied with a calibration certificateas standard, thus saving the user the cost of this ser vice in those situations wherea traceable calibration is required.

Each micrometer is marked with a serial number on the scale sleeve for easyidentification.

Extra large LCD displayThe special dustproof and jet-waterproof enclosure of the IP65 micrometer isprovided with a 30 percent larger LCD display when compared to the standardmodel, offering easy-to-read 7.5 mm high characters. This makes operation andhandling easier, as do the ergonomic ‘click action’ keys made fr om oil-resistantmaterials.

Certificate of Inspection

Automatic calibration

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The IP66 digital caliper with integrated absolute scale meets the r equirements ofthe highest level of protection against the ingress of dust and water jets accor dingto DIN EN 60529. This means it easily r esists powerful water jets projected fromall directions with a volume flow of 100 litr es per minute without any problems.This is considerably harsher treatment than can be expected under r ealisticoperating conditions.

Innovative enclosure gaskets and encapsulationsThe enormous endurance of this caliper – particularly when it comes to exposur eto oil and chemicals – was achieved thr ough the use of innovative enclosuregaskets and polyamide encapsulations as well as vulcanised nitrite rubberdeveloped especially for this purpose.

IP66 Digital Caliper.

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Gaskets

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The IP67 digital caliper offers an alternative water resistance rating to the IP66version by its ability to withstand temporary submersion in water or lubricantwithout sustaining damage.

IP67 requires full submersion of the instrument in water for 30 minutes. For thispurpose, the instrument tested must be positioned in a way that simulatesfrequent realistic operating situations. The lowest point of the enclosur e must lieone whole metre below the water sur face during the test.

Again, the enormousendurance of this caliper wasachieved through the use ofinnovative enclosure gasketsand polyamide encapsulationsas well as vulcanised nitriterubber developed especially forthis purpose.

IP67 Digital Caliper.

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100% safety testsLike the IP65 micrometer, the IP calipers also undergo a r eliability test on theproduction line in a test-tank/reference-tank setup. Instruments with defectivegaskets are immediately detected due to the pr essure loss in the test tank. Bymeans of this simulation the IP pr otection rating can be granted. In contrast tostandard sampling tests, each and every caliper is subject to this stringent testingwithout exception.

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Up to 1.7 years from just one batteryIn contrast to the previous models, which were powered by two button cells, thenew IP66/IP67 150 and 200 mm digital calipers operate with just one. Despite this,battery life can be up to 15,000 hours. This not only supports economy andprofitability but also helps to protect the environment.

IP safety test

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Calibration certificate supplied as standardEach caliper – up to 200 mm measuring range – is supplied with a calibrationcertificate as standard, thus saving the user the cost of this service in thosesituations where a traceable calibration is required. Each caliper and associatedcertificate carries a serial number for identification. This calibration certificate isinternationally acknowledged in accordance with ISO standards and includes allmetrological features of relevance in two languages and without extra charge. Thishigh-quality product is produced by an automatic calibration process and providestraceability to the international standard of length.

Automatic calibration

Certificate of Inspection

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IP66 digital scaleAn IP66 digital scale is available with the same pr otection levels against dust andwater jet ingress. Mitutoyo offers this efficient scale in three models withmeasuring ranges of 100, 150 and 200 mm.

Application example

Digital scales.

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In an extensive series of tests, micr ometers and calipers were exposed to variouslubricants to test the resistance of the instruments to these commonly usedproducts. In all tests, no adverse ef fect on functionality or material was detected.

ESSO Mobil Castrol Blaser

DRT45 Met 734,735,737 Honilo 130 Blasocut Kombi

DRT44,48,52 Met 303,411,414,417 Ilogrind 484

Honilo 171

Ilocut 670,JP-1

Ilocut 430,482,486

Ilogrind 483 Honio 480,481

Ilobroach 219

PNX 37 MetJ, 762,763,766 Ilobroach 30

Ilocut 103,334,603

Ilogrind 600SP

PNX 36, DRT52 Met 421,422,423,426 Varoocut C165

Ilocut 654,734

FNX32 Ilogrind 407,500FG

Honilo 981,988

Kutwell 40,EP61,M61 Hysol X

Super Cut50 Alsol B

SuperedgeJ, SW

Kutwell M62 Hysol AM,B

Syntilo R,DC

ClearedgeEP,500

Met 265 Syntilo 9974,9954,9913,1023

Syntilo* GX,81*,CR70

Lector SE Fluid180*

Anti Rust Safecoat

Rustilo

DOT 4

List of tested cutting lubricants.

Direction of travelPickup

coil

Magnetic field

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Inductive sensors and theABSOLUTE system.

The reliable electromagnetic sensorUnder the tough operating conditions of the typical shop floor , instruments areexposed to contaminants such as lubricant, water and dust which tend to get intoelectronic sensors and will interfere with correct operation of electrostatic types.This is because the dielectric properties of contaminants vary wildly (air = 1, water=80!) and, if they get into the gap between scale and pickup plates, will cause alarge change in output that is unr elated to pickup position. Thus, instrumentsusing electrostatic sensors have to be cleaned, car efully, which leads to inefficientworking, time loss and unreliable measuring results.

In contrast, instruments with electromagnetic sensor systems are completelyimmune to contamination effects because the magnetic properties of thesecontaminants are almost constant, so there is no change of output due to theirpresence in the gap between pickup and scale coils.

Electromagnetic induction sensor

Relative permeability of air, water,oil, etc. is practically the same

Relative permeabilityaround coils (Km)

hardly varies, so theinduced voltage is notaffected bycontaminationpenetrating the gapbetween them

Scale coil

Relativepermeability(magnetic property)around coils = Km

Induced current depends onrelative permeability around coils

Sensor gap free of contamination

Sensor gap contaminated

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Patented worldwide: The ABSOLUTE System by MitutoyoMitutoyo’s worldwide patent application for its innovative ABSOLUTE MeasuringSystem revolutionised the world of digital manual measuring instruments.

Calipers equipped with this system allow operation without having to r eset thereference point (zero point) each time. You set the zero point just once – this willthen be automatically ‘kept in mind’ by the measuring instr ument all the time…even if it is switched of f between measurements. After switching the instrumenton again you can continue measuring – without having to star t from the closed-jaw position and completely er ror-free. To put it simply, absolute instruments donot count up from zero: they ‘know’ where they are all the time. They do not‘travel’ a measuring section as conventional devices do – they ‘see’ it. Thisguarantees accurate, convenient, and time-saving measurements under allconditions.

Mitutoyo has not only developed and patented the ABSOLUTE System but has alsorefined it to ultimate perfection. As the only provider worldwide, Mitutoyo alsoimplements the original ABSOLUTE Technology in dial indicator probes andmicrometers (except for the IP65 type).

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NoteAll our pr oduct details, in particular the illustrations, drawings, dimension andperformance details and other technical specifications contained in this publication ar eto be considered to be approximate average values. To this extent, we reserve the rightto make changes in design, technical data, dimensions and weight. Our specifiedstandards, similar technical r ules and technical specifications, descriptions andillustrations of the pr oducts are correct at the time of printing. The cur rent version ofour general terms and conditions also apply . Only offers which we have submitted canbe considered to be definitive.

Mitutoyo (UK) Ltd

West Point Business Park

Andover, Hampshire

SP10 3UX, United Kingdom

Tel: (01264) 353123

Fax: (01264) 354883

E-mail: enquiries@mitutoyo.co.uk

www.mitutoyo.co.uk

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