PART 1505—REQUIREMENTS FOR ELECTRICALLY OPERATED TOYS OR OTHER ELECTRICALLY OPERATED ARTICLES INTENDED FOR USE BY CHILDREN Authority: 15 U.S.C. 1261-1262, 2079. Source: 38 FR 27032, Sept. 27, 1973, unless otherwise noted. Subpart A—Regulations § 1505.1 Definitions. (a) The following definitions apply to this part 1505: (1) The term “electrically operated toy or other electrically operated article intended for use by children” means any toy, game, or other article designed, labeled, advertised, or otherwise intended for use by children which is intended to be powered by electrical current from nominal 120 volt (110-125 v.) branch circuits. Such articles are referred to in this part in various contexts as “toy” or “electrically operated toy.” If the package (including packing materials) of the toy or other article is intended to be used with the product, it is considered to be part of the toy or other article. This definition does not include components which are powered by circuits of 30 volts r.m.s. (42.4 volts peak) or less, articles designed primarily for use by adults which may be used incidentally by children, or video games. (2) The term video games [38 FR 27032, Sept. 27, 1973, as amended at 58 FR 40335, July 28, 1993] § 1505.2 Scope of part. This part sets forth the requirements whereby electrically operated toys and other electrically operated articles intended for use by children (as defined in § 1505.1(a)(1)) are not banned toys or banned articles under § 1500.18(b)(1) of this chapter. § 1505.3 Labeling. (a) General. (b) Specific items. (i) The electrical ratings required by paragraph (c) of this section. (ii) Any precautionary statements required by paragraph (e) of this section. (iii) The date (month and year) of manufacture (or appropriate codes). As an alternative to putting this information on the toy itself, it may be included in the instructions provided with the toy (see paragraph (b)(3) of this section). (2) The shelf pack or package of the toy shall be labeled in accordance with the provisions of paragraph (d) of this section to indicate: (i) The date (month and year) of manufacture (or appropriate codes). (ii) The electrical ratings required by paragraph (c) of this section. (iii) Any precautionary statements required by paragraph (e) of this section. (3) Each toy shall be provided with adequate instructions that are easily understood by children of those ages for which the toy is intended. The instructions shall describe the applicable installation, assembly, use, cleaning, maintenance (including lubrication), and other functions as appropriate. Applicable precautions shall be included as well as the information required by paragraphs (b) (1) and (2) of this section, except that the date of manufacture information described in paragraph (b)(1)(iii) of this section need not be included in the instructions provided with the toy if it is placed on the toy itself. The instructions shall also contain a statement addressed to parents recommending that the toy be periodically examined for potential hazards and that any potentially hazardous parts be repaired or replaced. (4) If a toy is produced or assembled at more than one establishment, the toy and its shelf pack or package shall have a distinctive mark (which may be in code) identifying the toy as the product of a particular establishment. (c) Rating. (2) If a toy utilizes a single motor as its only electric energy consuming component, the electrical rating may be marked on a motor nameplate and need not be marked elsewhere on the toy if the nameplate is readily visible after the motor has been installed in the toy. (3) A toy shall be rated for alternating current only, direct current only, or both alternating and direct current. (4) The alternating current rating shall include the frequency or frequency range requirement, if necessary because of a special component. (d) Markings. (2) Minimum lettering heights shall be as follows: Surface Area Display Marking, Minimum Height of Lettering Square inches Inches Under 5 1 16 5 or more and under 25 1 8 25 or more and under 100 3 16 100 or more and under 400 1 4 400 or more 1 2 (e) Precautionary statements General. (2) Thermal hazards. (ii) Surfaces requiring precautionary statements of thermal hazards are those exceeding the following temperatures when measured by the test described in § 1505.6(g)(4): Surface type (see § 1505.6 (g)(2)) Thermal inertia type 1 Temperature Degrees C. Degrees F. C 1 65 149 C 2 75 167 C 3 85 185 C 4 95 203 D 1 55 131 D 2 70 158 D 3 80 176 D 4 90 194 1 Type 1: Greater than 0.0045 (e.g., most metals). Type 2: More than 0.0005 but not more than 0.0045 (e.g., glass). Type 3: More than 0.0001 but not more than 0.0005 (e.g., most plastics). Type 4: 0.0001 or less (e.g., future polymeric materials). The thermal inertia of a material can be obtained by multiplying the thermal conductivity (cal./em./sec./degrees C.) by the density (gm./cm. 3 (3) Lamp hazards Replaceable incandescent lamps. (ii) Nonreplacement incandescent lamps. (4) Water. [38 FR 27032, Sept. 27, 1973, as amended at 42 FR 34280, July 5, 1977; 42 FR 43392, Aug. 29, 1977] § 1505.4 Manufacturing requirements. (a) General. (2) Toys shall be produced in accordance with detailed material specifications, production specifications, and quality assurance programs. Quality assurance programs shall be established and maintained by each manufacturer to assure compliance with all requirements of this part. (3) The manufacturer or importer shall keep and maintain for 3 years after production or importation of each lot of toys (i) the material and production specifications and the description of the quality assurance program required by paragraph (a)(2) of this section, (ii) the results of all inspections and tests conducted, and (iii) records of sale and distribution. These records shall be made available upon request at reasonable times to any officer or employee of the Consumer Product Safety Commission. The manufacturer or importer shall permit such officer or employee to inspect and copy such records, to make such inventories of stock as he deems necessary, and to otherwise verify the accuracy of such records. (4) Toys shall be constructed and finished with a high degree of uniformity and as fine a grade of workmanship as is practicable in a well-equipped manufacturing establishment. Each component of a toy shall comply with the requirements set forth in this part. (b) [Reserved] (c) Protective coatings. (d) Mechanical assembly General. (2) Mounting. (3) Structural integrity. (e) Insulating material. (2) Material used to insulate a heating element from neighboring parts shall be suitable for the purpose. If plain asbestos in a glass braid is used to so insulate the heating element, it shall be tightly packed and totally enclosed by the braid, and the overall thickness, including the braid, shall not be less than one-sixteenth inch. Hard fiber may be used for electrically insulating bushings, washers, separators, and barriers, but is not sufficient as the sole support of uninsulated live metal parts. (f) Enclosures General. (2) Accessibility. (i) Shall be sealed by welding, riveting, adhesive bonding, and/or by special screws or other fasteners not removable with a common household tool (screwdriver, pliers, or other similar household tool) used as intended; and (ii) Shall have no opening permitting entry of a 0.010-inch-diameter music wire that could contact a live part. Cross-notch-head screws, spring clips, bent tabs, and similar fasteners shall not be considered suitable sealing devices for enclosures since they are easy to remove with common household tools. Bent tabs shall be acceptable if, due to metal thickness or other factors, they successfully resist forceful attempts to dislodge them with ordinary tools. (3) Nonapplication. (g) Spacings. (h) Special safety features Moving parts. 1/4 (2) Switch marking. (3) Electrically operated sewing machines. (4) Pressure relief valves. (5) Containers for heated materials. (6) Water. § 1505.5 Electrical design and construction. (a) Switches. (2) Switches shall be located and protected so that they are not subject to mechanical damage that would produce a hazard in normal use or from reasonably foreseeable damage or abuse (see § 1505.6(b)). (b) Lamps. (2) With all access doors and covers closed, the lamp enclosure shall have no opening that will permit entry of a straight rod 6 inches long and one-fourth inch in diameter if such entry would present an electrical hazard. The lamp shall be located no less than one-half inch from any 1/4 (3) A toy having one or more lampholders shall be designed and constructed so that no live parts other than the contacts of the lampholders are exposed to contact by persons removing or replacing lamps. The shells of all lampholders for incandescent lamps shall be at the same potential. (4) If the potential between the contacts of a lampholder for a replaceable incandescent lamp and any other part or ground is greater than 30 volts r.m.s. (42.4 volts peak), the contacts shall be located in an insulating husk or equivalent. (c) Transformers. (d) Automatic controls. (e) Power supply connections cords and plugs (2) A toy requiring a power cord shall have a flexible cord that is permanently attached to the toy. (3) The perimeter of the face of the attachment-plug cap shall be not less than five-sixteenths of an inch from any point on either blade of the plug. (4) The body of the attachment-plug cap shall decrease in cross section from the face but shall have an expansion of the body, after a suitable distance from the face, sufficient to provide an effective finger grip. (5) A flexible electrical power cord provided on a toy shall be type SP-2 (as defined in the “National Electrical Code,” Chapter 4, article 400, pages 230-241 (1978) 1 1 http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. Weight of appliance (without cord) and cord type 1/2 1/2 (6) A flexible cord and plug shall have a current-carrying capacity of not less than the ampere rating of the toy, and the conductor of the cord shall have a cross sectional area no less than No. 18 AWG (American wire gauge). (7) Cords on toys which are intended to come in direct contact with water or other liquids during use shall be of a jacketed type. Cords on toys with which water or other liquids are to be indirectly used (such as for cooling a mold) shall be plastic covered. (8) Transformers in which the primary coil connects directly to the branch circuit outlet shall not be subject to the requirements of paragraphs (e) (2), (4), and (5) of this section. (f) Bushings. (2) If a cord hole is in wood, porcelain, phenolic composition, or other suitable insulating material, the surface of the hole is acceptable without a bushing if the edges of the hole are smooth and well-rounded. Where a separate insulating bushing is required, a bushing made of ceramic material or a suitable molded composition is acceptable if its edges are smooth and well-rounded. (3) In no instance shall a separate bushing of wood, rubber, or any of the hot-molded shellac-and-tar compositions be considered acceptable. (g) Wiring. (2) Wireways shall be smooth and entirely free of sharp edges, burrs, fins, and moving parts that may abrade conductor insulation. Each splice and connection shall be mechanically secure, shall provide adequate and reliable electrical contact, and shall be provided with insulation at least equivalent to that of the wire involved unless adequate spacing between the splice and all other metal parts is permanently assured. (3) A wire connector for making a splice in a toy shall be a type that is applied by a tool and for which the application force of the tool is independent of the force applied by the operator. (4) Soldered connections shall be made mechanically secure before soldering. (5) Current-carrying parts shall be made of silver, copper, a copper alloy, or other electrically conductive material suitable for the particular application. (h) Strain relief. (2) If suitable auxiliary insulation is provided under a clamp for mechanical protection, clamps of any material are acceptable for use on Type SP-2 (as defined in the “National Electrical Code,” chapter 4, article 400, pages 184-194 (1971) 2 2 http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. (3) A flexible cord shall be prevented from being pushed into the toy through the cord-entry hole if such displacement would result in a hazardous condition. (4) A knot in the cord shall not be considered an acceptable means of strain relief, but a knot associated with a loop around a smooth, fixed structural component shall be considered acceptable. (i) Additional requirements. (Sec. 30(a), 86 Stat. 1231 (15 U.S.C. 2079(a))) [38 FR 27032, Sept. 27, 1973, as amended at 43 FR 45552, Oct. 3, 1978; 46 FR 63251, Dec. 31, 1981] § 1505.6 Performance. (a) General. (b) Enclosures. enclosure (1) Impact test. 1/2 (2) Compression test. 1/2 (3) Pressure test. (c) Handles and knobs General. (2) Crushing test. 1/2 (3) Lifting test. 1/2 (d) Stability. (e) Electrical Power input. (2) Dielectric strength. (ii) If a toy employs a low-voltage secondary winding (either in the form of a conventional transformer or as an insulated coil of a motor), the toy shall also be capable of withstanding without breakdown for 1 minute a sinusoidal test potential applied between the high-voltage and low-voltage windings. The test potential shall be applied at the rated frequency of the toy and shall have a value of 1,000 volts plus twice the rated voltage of the high-voltage winding. The test potential shall be supplied from a suitable capacity-testing transformer, the output voltage of which can be regulated. The waveform of the test voltage shall approximate a sine wave as closely as possible. (iii) The applied test potential shall be increased rapidly and uniformly from zero until the required test value is reached and shall be held at that value for 1 minute. Unless otherwise specified, the toy shall be at the maximum operating temperature reached in normal use prior to conducting the tests. (iv) The dielectric strength requirements of this subparagraph may also be determined by subjecting the toy to a 60-cycle-per-second (60 Hertz) essentially sinusoidal potential of 1,200 volts for 1 second. If the dielectric strength is determined by this method, the toy need not be in a heated condition. (3) Leakage current and repeated dielectric withstand tests. (A) Not have a leakage current exceeding 0.5 milliampere, except that during the interval beginning 5 seconds and terminating 10 minutes after the toy is first energized, the leakage current of toys with heating elements other than lamps shall not exceed 2.5 milliamperes; and (B) Comply with the requirements of a repeated dielectric withstand test both with and without preheating. (ii) All accessible parts of a toy shall be tested for leakage current. If an insulating material is used for the enclosure or part of the enclosure, the leakage current shall be measured using a metal foil with an area not exceeding 10 by 20 centimeters in contact with accessible surfaces of such insulating material. Where the accessible surface of insulating material is less than 10 by 20 centimeters, the metal foil shall be the same size as the surface. The metal foil shall be so applied that it will not affect the temperature of the toy. The accessible parts shall be tested individually, collectively, and from one part to another. (iii) Following the initial leakage current test, the toy shall be cooled down or heated up to 32 °C. (90 °F.). The toy shall then be conditioned for 48 hours in air at a temperature of 32° ±2 °C. (89.6° ±3.6 °F.) and with a relative humidity of 90-95 percent. The specified relative humidity shall be maintained inside a closed compartment in which a saturated solution of potassium sulphate is kept in a suitable container. Leakage current measurements shall be made, as specified in paragraph (e)(3)(ii) of this section and before the toy is energized, while the toy is in the humidity compartment. (iv) With the connections intended for the source of supply connected thereto and then connected to the ungrounded side of a power supply circuit having a voltage equal to 110 percent of the rated voltage of the toy, the leakage current through a noninductive 1,500-ohm resistor connected between the gounded side of the supply circuit and each dead metal part (accessible and inaccessible) shall, when stable, be measured in accordance with the test provisions established in ANSI Standard C 101.1-1971, “American National Standard for Leakage Current for Appliances,” approved November 17, 1970, which is incorporated by reference. Copies of this document are available from American National Standards Institute, 1430 Broadway, New York, New York 10018. This document is also available for inspection at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. (v) For a toy whose outer enclosure consists wholly or partly of insulating material, the term dead metal part (4) Motor operation. (ii) A motor-operated toy shall be tested with the motor stalled if the construction of the toy is such that any person can touch moving parts associated with the motor from outside the toy. The performance of the toy shall be considered unacceptable if, during the test, temperatures higher than those specified in § 1505.8 are attained or if temperatures higher than those specified for Type C surfaces in § 1505.7 are attained on any accessible surface of the motor. (See also § 1505.50.) (5) Overload Motor. (ii) Switch. (f) Hydrokinetic General. (2) Preliminary test. (3) Pressure-relief test. (4) Operating pressure test. (5) Hydrostatic test. (g) Thermal General. (2) Classification. 1/4 (i) Type A. (ii) Type B. a 7/16 1/4 b (iii) Type C. a b (iv) Type C marked. (v) Type D. (vi) Type D marked. (vii) Type E. (3) Requirements. (4) Test conditions General. (ii) Temperature. (iii) Voltage. (5) Temperature measurements General. http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. (ii) Test procedures. (iii) Heating devices. (h) Strain-relief test. (2) The initial 2-minute test shall be conducted with the force vector parallel to the longitudinal axis of the cord and perpendicular to the anchoring surface of the strain-relief unit. Each test at other angles of stress shall be conducted for periods of 1 minute. The strain-relief means is not acceptable if, at the point of disconnection of the cord, there is any movement of the cord to indicate that stress would have resulted on the conections. (3) Except for toys weighing more than 10 pounds, the strain-relief unit and its support base shall be designed and constructed in such a manner that no indication of stress would result which would produce a hazard when the cord is held firmly in place 3 feet from the strain-relief unit and the toy is dropped the 3 feet at any angle. [38 FR 27032, Sept. 27, 1973; 38 FR 30105, Nov. 1, 1973, as amended at 43 FR 26428 June 20, 1978; 46 FR 63251, Dec. 31, 1981; 51 FR 34199, Sept. 26, 1986] § 1505.7 Maximum acceptable surface temperatures. The maximum acceptable surface temperatures for electrically operated toys shall be as follows: Surface type (as described—in § 1505.6 (g)(2)) Thermal inertia type 1 Temperatures °C. °F. A 1 50 122 A 2 55 131 A 3 60 140 B 1 55 131 B 2 65 149 B 3 75 167 C (unmarked) 1 65 149 C (unmarked) 2 75 167 C (unmarked) 3 85 185 C (unmarked) 4 95 203 C marked 1 70 158 C marked 2 90 194 C marked 3 110 230 C marked 4 130 266 D (unmarked) 1 55 131 D (unmarked) 2 70 158 D (unmarked) 3 80 176 D (unmarked) 4 90 194 D marked 1 60 140 D marked 2 75 167 D marked 3 100 212 D marked 4 125 257 E ( 2 ( 3 ( 3 1 Type 1: Greater than 0.0045 (e.g., most metals). Type 2: More than 0.0005 but not more than 0.0045 (e.g., glass). Type 3: More than 0.0001 but not more than 0.0005 (e.g., most plastics). Type 4: 0.0001 or less (e.g., future polymeric materials). The thermal inertia of a material can be obtained by multiplying the thermal conductivity (cal./cm./sec./degrees C.) by the density (gm./cm. 3 2 3 § 1505.8 Maximum acceptable material temperatures. The maximum acceptable material temperatures for electrically operated toys shall be as follows (Classes 105, 130, A, and B are from “Motors and Generators,” Standard MG-1-1967 1 1 Material Degrees C. Degrees F. Capacitors ( 1 ( 1 Class 105 insulation on windings or relays, solenoids, etc.: Thermocouple method 2 90 194 Resistance method 110 230 Class 130 insulation system 110 230 Insulation: Varnished-cloth insulation 85 185 Fiber used as electrical insulation 90 194 Class A Class B Class A Class B Insulation on coil windings of a.c. motors (not including universal motors) and on vibrator coils: In open motors and on vibrator coils—thermocouple or resistance method 2 100 120 212 248 In totally enclosed motors—thermocouple or resistance method 2 105 125 221 257 Insulation on coil windings of d.c. motors and of universal motors: In open motors: Thermocouple method 2 90 110 194 230 Resistance method 100 120 212 248 In totally enclosed motors: Thermocouple method 2 95 115 203 239 Resistance method 105 125 221 257 Phenolic composition 3 150 302 Rubber- or thermoplastic-insulated wires and cords 3 60 140 Sealing compound ( 4 ( 5 Supporting surface while the toy is operating normally 90 194 Wood and other similar combustible material 90 194 1 2 3 4 5 Subpart B—Policies and Interpretations § 1505.50 Stalled motor testing. (a) § 1505.6(e)(4)(ii) requires that a motor-operated toy be tested with the motor stalled if the construction of the toy is such that any person can touch moving parts associated with the motor from outside the toy. The performance of the toy shall be considered unacceptable if, during the test, temperatures higher than those specified in § 1505.8 are attained or if temperatures higher than those specified for Type C surfaces in § 1505.7 are attained on any accessible surface of the motor. (b) To determine if a moving part associated with the motor can be touched from outside the toy, the Commission staff will use a 1/4 (c) The requirement that temperatures higher than those specified in § 1505.8 not be attained applies to those internal components which are described in § 1505.8. Additionally, temperatures of accessible surfaces shall not exceed those specified for Type C surfaces in § 1505.7. (Secs. 2(q)(1)(A), 2(r), 3(e), 10(a), 74 Stat. 372, 378, 80 Stat. 1303-1304, 83 Stat. 187-189 (15 U.S.C. 1261, 1262, 1269); sec. 30(a), 86 Stat. 1231 (15 U.S.C. 2079(a))) [43 FR 26428, June 20, 1978] § 1505.51 Hot surfaces. (a) Test probe. 1/4 (b) Accessibility of Type C and C-marked surfaces. [51 FR 34199, Sept. 26, 1986]