Festool Drill C12 EC TEC User Manual

Technical Review of  
the C12 EC-TEC  
Cordless Drill  
By Rick Christopherson  
Once again, Festool has shattered the expectations  
of the drill industry with the release of the new  
C12 cordless drill. The C12 is not just a cosmetic  
change made to an existing design. The C12 is  
packed with revolutionary motor and control  
technology on several levels. Festool didn't just  
leap forward in one area of this drill; they made  
To circumvent the  
losses of the  
brushed motor,  
Festool  
incorporated a  
brushless DC  
motor2 into the  
huge leaps forward in ALL areas of this drill. From new C12 drill.  
the motor, to the electronics, to the geartrain; this  
drill raised the bar just past the fingertips of the  
competition.  
The electrical  
connections to  
the windings are  
permanent, and  
don't suffer from  
the inefficiencies  
EC -TEC ® Motor Tec hnology  
The heart of the C12 is the revolutionary EC-TEC  
brushless motor. This isn't just your run-of-the-  
mill motor. This is a permanent magnet, remotely  
commutated, 3-phase, AC motor. This is the same  
type of motor used as servo motors in robotic  
systems where high torque, high speed, and  
extreme durability are crucial.  
of constantly  
connecting and disconnecting as the motor rotates.  
The brushless DC motor lasts longer, and requires  
no maintenance, as compared to the brushed  
motor. It is also smoother and quieter.  
Elec tronic s  
So just how unique is this motor? Well, if you  
mechanically turned the motor, it would generate  
a 3-phase, sinusoidal AC output; just like  
industrial diesel-electric generators do. (Do not  
attempt this.1)  
There are some popular brand drills on the market  
that are known to destroy themselves under a  
normal, but heavy load. I know this first-hand  
because I "smoked" a couple drills during my  
investigation of drills (including the most  
For years, the motor technology of cordless tools  
has not changed. The brushed DC motor has been  
the staple—albeit inefficient—motor for ages. The  
brushed motor is simple, compact, and  
inexpensive, but it suffers from inefficient use of  
limited battery power. The greatest weakness of  
the brushed motor is that the electricity to the  
motor's windings passes through an electrical  
connection that is constantly changing and  
moving. Every time you see the brushes spark  
inside of a brushed motor, it is a waste of energy  
that is not available for use by the motor.  
expensive drill my local home center carried).  
A powerful drill is of little value if it is easily  
damaged. The C12 has an intelligent electronic  
controller that not only powers the motor, but  
more importantly, monitors its health. Unlike  
other drills on the market, the C12 won't let you  
destroy the drill (or the battery) no matter how  
hard you try.  
It took less that 30 seconds to destroy a $270, 18-  
volt drill, yet the 12-volt C12 handled the same  
1 Never attempt to manually turn the output shaft of any  
Festool drill or connect this drill to the output shaft of  
another drill. The C12's output shaft has a mechanical lock  
for bit changing and cannot be rotated manually.  
2 Even though this is a 3-phase, AC motor; it is the electronic  
industry's practice to refer to this as a brushless DC (BLDC)  
motor because the AC power signal is electronically created  
and controlled from a DC (battery) power source.  
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asked of it, the drill will shut down to protect the  
battery.  
clutch for this purpose. What is new is how  
Festool has implemented a motor cut-out feature  
into the slip clutch.  
This is an important feature that might be  
misunderstood by many users. Even though the  
drill seems to have plenty of power for a moderate  
load, if you try to take a heavy load from a low  
battery, it will shut down the motor to protect the  
battery. Other drills will allow you to over-draw  
the battery and shorten its life.  
If you are anything like me, the grinding sound of  
a slipping torque clutch is like fingernails on a  
blackboard. I hate that sound so much that I refuse  
to use the torque cut-out feature on a drill. Much  
to my elation, Festool has found a unique way to  
ease my pain.  
The slip clutch on the C12 will slip only half a  
revolution before the motor detects the slippage  
and shuts down. No more do I have to put up with  
the endless grinding sound from the slip clutch.  
G ea rbox  
The C12 gearbox is virtually bulletproof. To  
harness the power of the motor, the C12 uses a 3-  
stage planetary geartrain. This is the same type of  
gear set used in automotive transmissions for its  
strength and versatility.  
For reliability, the C12 still uses the common slip  
clutch design found on many other drills. Spring  
loaded steel balls press against the recesses of the  
clutch ring. When the torque of the motor exceeds  
the force of the spring loaded balls, the clutch ring  
spins, which disables the first-stage planetary  
gear set.  
This design is commonly used because  
it is robust, and only a tiny fraction of  
the motor's power is needed to disengage  
the clutch ring. As a matter of fact, the  
pressure on the clutch balls is less than  
what it takes to click a ballpoint pen.  
In a planetary drive,  
To detect when the clutch ring is slipping  
(rotating), two small, rare earth magnets are  
inserted into the clutch ring. When these pass by a  
sensor located inside the motor housing, a signal is  
sent to the controller, and the controller turns off  
the motor.  
the power of the motor is shared by dozens of gear  
teeth instead of just a couple. It also permits for a  
very high gear ratio in a small amount of space.  
This type of geartrain allows the motor to spin at  
very high RPM, and produce very high torque  
levels at the output shaft via gear reduction.  
Switching between high-speed and low-speed  
gears, simply disables or enables the mid-stage  
planetary gear set.  
Elec tromec ha nic a l C lutc h  
a nd Motor C ut-Out  
For driving screws, the C12 has a 24-position  
torque clutch selector. This allows you to  
determine at what power level the drill stops  
turning to prevent breaking or stripping screws.  
This is nothing new, as most drills have a slip-  
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Another feature of the C12 gearbox is the integral  
shaft-lock to assist in bit changing. The motor can  
rotate the drill chuck, but the drill chuck cannot  
rotate the motor. With the shaft-lock, you can  
tighten the chuck as hard as you want, and the  
gearbox will hold fast.  
C onc lusion  
I'm not big on drawing conclusions for others to  
follow. I am more comfortable writing fact-based  
information. So instead, I will use this space to  
provide some of the opinion-based information I  
came across during my examination. It might be  
a hodge-podge of ideas, but I guess that's what  
opinions are supposed to be.  
controller I cannot state this as fact, so I am  
leaving it as just my opinion.  
My excitement just kept escalating from there on.  
So the next thing I did was build a dynamometer  
so I could compare the power of this 12-volt drill  
against several 14 and 18-volt drills I bought at  
my local home center.  
I first saw a cutaway model of the C12 at the  
AWFS trade show in Las Vegas this summer (see  
the cutaway picture on page 2). I was so  
fascinated with the idea that a 3-phase motor was  
being used in a battery operated tool that I  
volunteered to write this technical review and  
give it to Festool without taking a fee for my  
work.  
Unfortunately, when the three most popular  
drills on the market (names withheld) started  
smoking under my dynamometer's load, I  
decided it would not be wise to publish this data,  
lest I wanted a lawsuit. However, I found it very  
curious that the only drills with torque curves  
higher than the C12 were also the ones that  
allowed their motors to self-destruct.  
With technology this cutting-edge, I knew there  
would be a lot of people that were not yet  
familiar with it (including myself). Besides, I was  
dying for a chance to tear this drill apart to see  
how it worked (I am a card-carrying member of  
tool-junkies anonymous).  
I could have legitimately published the rest of  
the data, and throw out outlying data because  
the drills destroyed themselves to achieve their  
results. Instead, I decided to throw out the entire  
test, because trying to explain the outliers might  
have sounded like I was playing games with the  
data; and I refuse to publish anything that  
sounds misleading.  
While it wasn't very scientific, one of the first  
things I did when the drill arrived was to try to  
drive a 4-inch screw into a block of wood; except  
I wanted to see what would happen at ultra-  
ultra-low speed—about 1 revolution per second.  
I carefully held the trigger in a fixed position so  
the bit was spinning at a constant speed, and  
then started the screw into the wood. I can't even  
begin to tell you just how blown away I was  
when the drill kept plodding along until the  
entire 4-inch screw was sunk into the wood. I  
tried the same thing with one of my other drills,  
and it stalled after just 1 inch.  
Finally, there are a lot of intangibles about this  
drill that don’t fit neatly into a technical review.  
Here are some other quick observations:  
The motor is extremely smooth and quiet;  
noticeably so over other cordless drills.  
The drill is perfectly balanced, with the center  
of balance right over the trigger—you can  
balance the drill on your index finger.  
Even with the largest optional batteries, the  
drill is still very light.  
Changing batteries is very easy because the  
batteries slide in from the front, and the latches  
don't need to support the weight of the battery  
like most other drills.  
Oh by the way, I wasn’t doing this in low-gear  
like you would expect. The drill was in high-  
gear! The motor appears to deliver a constant  
torque at any speed or load. However, without  
seeing the schematic of the motor's electronic  
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The C12 comes with the compact Centrotec bit  
holder, as shown, but also includes the  
standard keyless chuck (top image of the three  
attachments). The optional offset and right-  
angle chucks (lower two images) are awe  
inspiring, and are a "must have" accessory in  
my opinion.  
My Background: I am an electrical engineer, and my  
current occupation is Sr. Technical Writer for an  
international corporation. I use my engineering  
background to write technical repair manuals for  
sophisticated equipment, including such things as  
lasers, robotic systems, and smartcard programmers,  
to name a few.  
In the past, I owned and operated a custom cabinet  
shop, and am the true definition of a "tool junkie". I  
also use to perform "tool tests" for several  
woodworking magazines.  
A year ago I was introduced to Festool products, and  
was so impressed with them that I began rewriting  
some of their owner's manuals in my spare time.  
Supplement: How Variable Speed Controllers Work  
A common misconception about variable speed  
tools is that the speed is controlled with a variable  
resistor, like the dimmer of a light switch. This  
doesn’t work well for motors for two reasons.  
This type of motor speed control is called Pulse  
Width Modulation (PWM), and is also used in many  
other applications to control power. Most recently,  
even the old resistive light dimmers are being  
First, is because energy is wasted pumping current replaced by solidstate PWM light dimmers,  
through the resistor. The second reason is that  
whatever power that is not being used by the  
motor has to be dissipated by the resistor. This  
means that the battery would be providing full  
power at all times, regardless how slow the motor  
is turning. This would be like driving your car  
with the gas pedal pressed all the way to the floor,  
and trying to drive at the speed limit by constantly  
pressing the brake pedal.  
because they are more efficient and do not pose a  
fire hazard from overheating.  
With a PWM motor control, the power pulses turn  
on at a constant interval, but the duration of the  
pulse is varied, as shown below. The longer the  
pulses, the more current flowing through the  
motor, and the faster it spins. When full power is  
needed, the PWM circuitry is bypassed, and full  
battery power is delivered to the motor.  
A more efficient way to control the speed of a  
motor is to turn it on and off very rapidly. The  
more the motor is turned on, versus turned off, the  
faster it spins. Keep in mind that this switching is  
happening so fast (several hundred times a  
second) that the inertia of the motor keeps it  
spinning smoothly.  
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