Safety of industrial trucks - Electrical requirements -
Contents
1. functions shall be relieved of mechanical strain at their electrical termination 5 4 7 Identification Wires cables terminals etc shall be identified by codings in accordance with the electrical diagram included in the service manual 5 5 Protection against electric shock Exposed high tension ignition terminals on trucks shall be protected against direct contact by barriers or insulated caps 6 Information for use NOTE The main information for use is detailed in the truck standards as listed in the foreword The following are additional requirements 6 1 Electrical diagram An electrical diagram which shall include nominal battery voltage and where applicable frame polarity shall be included in the service manual Connection points for auxiliary lighting shall be indicated 6 2 Safety checks Methods and intervals for checking safety systems shall be included in the service manual or instruction handbook STD BST BS EN 1175 2 ENGL 1998 WE Lb24bb9 0698293 beT EE Page 6 EN 1175 2 1998 Annex A informative Clauses of this European Standard addressing essential requirements or other provisions of EU Directives This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association and supports essential safety requirements of EU Directives 89 392 EEC as amended by 91 368 EEC 93 44 EEC and 93 68 EEC WARNING Other requirements and other EU Direct2. isches Komitee fiir Normung Central Secretariat rue de Stassart 36 B 1050 Brussels 1998 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members Ref No EN 1175 2 1998 E Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS Not for Resale STD BST BS EN 1175 2 ENGL 1998 EE 1624469 0698289 179 EE Page 2 EN 1175 2 1998 Foreword This European Standard has been prepared by Technical Committee CEN TC 150 Industrial trucks Safety the secretariat of which is held by BSI This European Standard shall be given the status of a national standard either by publication of an identical text or by endorsement at the latest by July 1998 and conflicting national standards shall be withdrawn at the latest by July 1998 This European Standard has been prepared under a mandate given to CEN by the European Commission and the European Free Trade Association and supports essential requirements of EU Directive s This European Standard is one of a package of standards for the safety of industrial trucks prEN 1726 Safety of machinery Industrial trucks Self propelled trucks up to and including 10 000 kg capacity and tractors with a drawbar pull up to and including 20 000 N prEN 1726 2 Safety of industrial trucks Self propelled trucks up to and including 10 000 kg c
3. NOTE 1 Part 3 of this standard details specific electrical Page 3 EN 1175 2 1998 2 Normative references This European Standard incorporates by dated or undated reference provisions from other publications These normative references are cited at the appropriate places in the text and the publications are listed hereafter For dated references subsequent amendments to or revisions of any of these publications apply to this European Standard only when incorporated in it by amendment or revision For undated references the latest edition of the publication referred to applies EN 292 1 1991 Safety of machinery Basic concepts general principles for design Part 1 Basic terminology methodology EN 292 2 1991 Safety of machinery Basic concepis general principles for design Part 2 Technical principles and specifications EN 954 1 1996 Safety of machinery Safety related parts of control systems Part 1 General principles Sor design EN 1050 1996 Safety of machinery Principles for risk assessment requirements for electrical power transmission systems of internal EN 60947 5 1 1991 Low voliage switchgear and combustion engine powered trucks controlgear Part 5 Control circuit devices and gt NOTE 2 Reference is made to this standard in other standards switching elements Section one Electromechanical which cover the non electrical requirements of the various control circuit devices I
4. of industrial trucks Automated Junctions of trucks prEN 1755 Safety of industrial trucks Operation in potentially explosive atmospheres Use in flammable gas vapour mist and dust prEN 12053 Safety of industrial trucks Test methods for measuring noise emission prEN ISO DIS 13564 Test method for measuring visibility from self propelled trucks prEN 13059 Safety of industrial trucks Test methods for measuring vibration prEN 12895 Industrial trucks Electromagnetic compatibility For relationship with EU Directive s see informative Annex ZA which is an integral part of this standard According to the CEN CENELEC Internal Regulations the national standards organizations of the following countries are bound to implement this European Standard Austria Belgium Czech Republic Denmark Finland France Germany Greece Iceland Ireland Italy Luxembourg Netherlands Norway Portugal Spain Sweden Switzerland and the United Kingdom Contents Page Foreword Introduction 1 Scope 2 Normative references 3 Definitions 4 List of hazards 5 General requirements Starter battery Insulation Constraining Disconnection Protection of circuits Safety related control systems Low voltage Frame fault Load handling control Speed limitation Steering control Wiring practices conductors and electrical components Protection Cross sectional area Specification Fuel leakage Mechanical protection Wiring that fle
5. EC 947 5 1 1990 pala igi ISO 5053 1987 Powered industrial trucks NOTE3 This standard does not address the subject of see X electromagnetic compatibility EMC Terminology n NOTE 4 The special requirements for operation in potentially explosive atmospheres are not covered in this standard 3 Definitions 1 2 The requirements of this standard are applicable when trucks are operated under the following climatic conditions Maximum ambient temperature For the purposes of this standard definitions given in ISO 5053 1987 apply together with the following 3 1 nominal battery voltage continuous duty 40 C the total number of battery cells connected in series Lowest ambient temperature 20 C multiplied by 2 V for conventional lead acid batteries Service altitude up to 2 000 m and by 1 2 V for alkaline batteries For other types of i batteries corresponding definitions apply Relative humidity in the range 30 to 95 non condensing 1 3 This standard covers specific hazards which could occur during the intended use of trucks For hazards occurring during construction transportation commissioning de commissioning and disposal reference should be made to EN 292 4 List of hazards The following significant hazards from annex A of EN 1050 1996 within brackets are applicable in the situations described and could involve risks to persons if not reduced or eliminated The corresponding requirem
6. STD BST BS EN 11 5 2 ENGL 1998 MM 1424469 0658284 4OT EE BRITISH STANDARD BS EN a mma 1175 2 1998 Safety of industrial trucks Electrical requirements Part 2 General requirements for internal combustion engine powered trucks S TIM The European Standard EN 1175 2 1998 has the status of a British Standard ICS 53 060 NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS Not for Resale STD BSTI BS EN 1175 2 1998 BS EN 11 S 2 ENGL 1998 MM 1b24bbL9 0698247 32b EE This British Standard having been prepared under the direction of the Engineering Sector Board was published under the authority of the Standards Board and comes into effect on 15 May 1998 BSI 1998 ISBN 0 580 29139 1 Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS National foreword This British Standard is the English language version of EN 1175 2 1998 The UK participation in its preparation was entrusted to Technical Committee MHE 7 Industrial trucks which has the responsibility to aid enquirers to understand the text present to the responsible European committee any enquiries on the interpretation or proposals for change and
7. apacity and tractors with a drawbar pull up to and including 20 000 N Part 2 Additional requirements Jor trucks with elevating operator position and trucks specially designed to travel with elevated load prEN 1551 Safety of industrial trucks Self propelled trucks over 10 000 kg capacity prEN 1459 Safety of industrial trucks Variable reach trucks prEN 1757 1 Safety of industrial trucks pedestrial controlled manual and semi manual trucks Part 1 Stacker trucks prEN 1757 2 Safety of industrial trucks pedestrial controlled manual and semi manual trucks Part 2 Pallet trucks with lift height up to 300 mm prEN 1757 3 Safety of industrial trucks pedestrial controlled manual and semi manual trucks Part 3 Platform trucks prEN 17574 Safety of industrial trucks pedestrial controlled manual and semi manual trucks Part 4 Scissor lift pallet trucks EN 1525 Safety of industrial trucks Drivertess trucks and their systems EN 1175 1 Safety of industrial trucks Electrical requirements Part 1 General requirements for battery powered trucks EN 1175 2 Safety of industrial trucks Electrical requirements Part 2 General requirements for internal combustion engine powered trucks EN 1175 3 Safety of industrial trucks Electrical requirements Part 3 Specific requirements for the electric power transmission systems of internal combustion engine powered trucks EN 1526 Safety
8. auxiliary circuits shall be fuse protected against short circuit conditions and dangerous excess current Several auxiliary circuits in parallel with combined rated current not exceeding 12 A may be protected by a single device Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS 5 1 2 5 3 4 5 3 5 Battery constraint Speed limitation Steering control Battery insulation Protection of circuits Protection Cross sectional area Specification 5 4 5 Mechanical protection 5 4 6 Wiring that flexes 5 5 Protection against electric shock 5 1 2 Battery constraint 5 4 4 Fuel leakage Identification Information for use 5 4 2 5 4 3 Battery disconnection Protection of circuits Low voltage Frame faults Load handling control Speed limitation Steering control Specification Fuel leakage Mechanical protection Wiring that flexes 5 3 3 5 3 4 5 3 5 5 4 38 5 4 4 5 4 5 5 4 6 5 3 Safety related control systems 5 3 1 Low voltage Electrical control systems shall be so designed that all functions operate and safety is not jeopardized if the voltage should fall below the nominal battery voltage by as much as 15 NOTE Where a system is required to function during engine starting condition special precautions can be required 5 3 2 Frame faults The electric circuits shall be so designed or protected that frame faults shall
9. ents are designed to limit the risk or remove the hazard in each situation RST 1998 Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS Not for Resale STD BSI BS EN 1175 2 ENGL 1998 MM 1624669 06978291 857 EE Page 4 EN 1175 2 1998 Corresponding requirements 4 1 Mechanical hazards 1 4 1 1 Crushing hazard 1 1 4 1 2 Impact by collision 1 6 4 1 2 1 when driven by the operator 4 1 3 Loss of stability 1 11 from excess speed from faulty battery mass 4 2 Electrical hazards 2 4 2 1 Electric shock 2 1 4 2 2 Short circuit 4 2 3 Overloading Hazards generated by substances 7 Ergonomic hazards 8 Human error 8 6 when the truck is serviced Hazards due to functional disorders 10 5 General requirements 5 1 Starter battery 5 1 1 Insulation Any live parts of the battery not connected to the frame shall be insulated 5 1 2 Constraining Batteries of all trucks shall be constrained to prevent displacement which may give rise to danger 5 1 3 Disconnection Trucks shall be so designed and constructed that the battery can be electrically disconnected with the aid of an easily accessible device e g a switch or connector Disconnectable battery terminals satisfy this requirement providing the terminals are accessible without the use of a key or tool 5 2 Protection of circuits Control and
10. is British Standard would inform the Secretary of the technical committee responsible the identity of which can be found on the inside front cover Tel 0181 996 9000 Fax 0181 996 7400 BSI offers members an individual updating service called PLUS which ensures that subscribers automatically receive the latest editions of standards Buying standards Orders for all BSI international and foreign standards publications should be addressed to Customer Services Tel 0181 996 7000 Fax 0181 996 7001 In response to orders for international standards it is BSI policy to supply the BSI implementation of those that have been published as British Standards unless otherwise requested Information on standards BSI provides a wide range of information on national European and international standards through its Library and its Technical Help to Exporters Service Various BSI electronic information services are also available which give details on all its products and services Contact the Information Centre Tel 0181 996 7111 Fax 0181 996 7048 Subscribing members of BSI are kept up to date with standards developments and receive substantial discounts on the purchase price of standards For details of these and other benefits contact Membership Administration Tel 0181 996 7002 Fax 0181 996 7001 Copyright Copyright subsists in all BSI publications BSI also holds the copyright in the UK of the publications of the international
11. ives may be applicable to the product s falling within the scope of this standard The following clauses of this standard are likely to support requirements of the above referred Directive Compliance with this standard provides one means of conforming with the specific essential requirements of the Directive concerned and associated EFTA regulations Table ZA 1 Essential health and safety requirements 21 Safiy and reabiity of cont systems s3 O OO OOOO O O e O SSCS C S mra msmo OOOO ooo o 623 Excos seeded SSSSC S S SBBASSSCSCSCSC C S S S 6a Risks of the carer fling or overuming p84 BSI 1998 Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS Not for Resale STD BST BS EN L175 2 ENGL 1998 MM 1624669 0698294 Sbb ME BS EN 1175 2 1998 BSI British Standards Institution BSI is the independent national body responsible for preparing British Standards It presents the UK view on standards in Europe and at the international level It is incorporated by Royal Charter Revisions British Standards are updated by amendment or revision Users of British Standards should make sure that they possess the latest amendments or editions It is the constant aim of BSI to improve the quality of our products and services We would be grateful if anyone finding an inaccuracy or ambiguity while using th
12. keep the UK interests informed monitor related international and European developments and promulgate them in the UK A list of organizations represented on this committee can be obtained on request to its secretary Cross references The British Standards which implement international or European publications referred to in this document may be found in the BSI Standards Catalogue under the section entitled International Standards Correspondence Index or by using the Find facility of the BSI Standards Electronic Catalogue A British Standard does not purport to include all the necessary provisions of a contract Users of British Standards are responsible for their correct application Compliance with a British Standard does not of itself confer immunity from legal obligations Summary of pages This document comprises a front cover an inside front cover the EN title page pages 2 to 6 an inside back cover and a back cover Amendments issued since publication Amd No Text affected Not for Resale STD BSI BS EN 1175 2 ENGL 19958 MM 1b24bb9 04942848 2be EE EUROPEAN STANDARD EN 11752 NORME EUROPEENNE EUROPAISCHE NORM January 1998 ICS 53 060 Descriptors Industrial trucks heat engines safety of machines accident prevention hazards tests electrical installation design control devices protection against electric shocks wiring utilization information English version Safety of industrial t
13. not cause inadvertent movements that cannot be controlled by the driver 5 3 3 Load handling control Electrical and electronic control load handling systems shall be arranged so that in case of a fault the load handling movement can be stopped The safety related parts shall be in accordance with category 1 in EN 954 1 1996 This requirement is not necessary where the movements are controlled by some other means e g direct manually operated hydraulic valves BSI 1998 Not for Resale aa STD BSI BS EN 1175 2 ENGL 1998 EE 5 3 4 Speed limitation For limiting or reducing the speed of a function on trucks designed to travel with an elevated operator and or load for stability reasons the following shall apply a The electrical and electronic circuits shall be so designed and fitted that in the event of electrical faults the speed limitation is preserved or the motion shall be brought to a controlled stop Restarting shall not be possible until the circuit has been restored Where it is not possible to satisfy the above requirements by a simple electrical or electronic circuit the electrical or electronic circuits may be duplicated Facilities shall be provided to check the correct functioning at service intervals in accordance with the manufacturer s instructions The safety related parts shall be in accordance with category 2 in EN 954 1 1996 b Mechanically operated switches may be of a positive action type in acco
14. rdance with EN 60947 5 1 1991 such that they disconnect the circuit Other switches can be used providing the system meets the safety requirements in a above 5 3 5 Steering control Electrical and electronic steering control systems shall be arranged so as to avoid operation of the steering system unrelated to the manual input during travel Any electrical or electronic fault capable of producing the above condition shall be detected and the steering assistance de energized within 0 1 s Where the power steering system is fully dependent on the electrical power source the truck shall also be brought to a controlled stop automatically It shall be possible to check the operation of the safety circuit of this system at service intervals in accordance with the manufacturer s instructions The safety related parts shall be in accordance with category 3 in EN 954 1 1996 5 4 Wiring practices conductors and electrical components One pole of the electrical system may be connected to the truck frame 5 4 1 Protection All conductors not connected to the truck frame shall be either effectively insulated and where necessary protected against thermal and mechanical damage or shall be so placed and safeguarded as to avoid danger when the truck is in its normal operating condition 5 4 2 Cross sectional area The cross sectional area of conductors shall be so selected that during operation of the truck the temperature does not exceed
15. rucks Electrical requirements Part 2 General requirements of internal combustion engine powered trucks S curit des chariots de manutention Sicherheit von Flurf rderzeugen Elektrische Prescriptions lectriques Partie 2 Prescriptions Anforderungen Teil 2 Allgemeine Anforderungen g n rales des chariots quip s d un moteur f r Flurforderzeuge mit Verbrennungsmotoren thermique This European Standard was approved by CEN on 23 November 1997 CEN members are bound to comply with the CEN CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration Up to date lists and bibliographical references concerning such national standards may be obtained on application to the Central Secretariat or to any CEN member This European Standard exists in three official versions English French German A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the Central Secretariat has the same status as the official versions CEN members are the national standards bodies of Austria Belgium Czech Republic Denmark Finland France Germany Greece Iceland Ireland Italy Luxembourg Netherlands Norway Portugal Spain Sweden Switzerland and United Kingdom S L CEN European Committee for Standardization Comit Europ en de Normalisation Europ
16. standardization bodies Except as permitted under the Copyright Designs and Patents Act 1988 no extract may be reproduced stored in a retrieval system or transmitted in any form or by any means electronic photocopying recording or otherwise without prior written permission from BSI This does not preclude the free use in the course of implementing the standard of necessary details such as symbols and size type or grade designations If these details are to be used for any other purpose than implementation then the prior written permission of BSI must be obtained If permission is granted the terms may include royalty payments or a licensing agreement Details and advice can be obtained from the Copyright Manager Tel 0181 996 7070 BSI 389 Chiswick High Road London W4 4AL Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS Not for Resale
17. the temperature rating of insulation used RST 1998 Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS Not for Resale Lbe4bb9 0L98292 793 EE Page 5 EN 1175 2 1998 5 4 3 Specification Copper conductors external to enclosures excluding short connections between electric or electronic components and wires that are an integral part of a proprietary component shall be a flexible b of cross sectional area not less than 1 for control wiring 0 50 mm 2 for signal wiring 0 30 mm 3 for data communication wiring and for conductors of adequately supported copper multicore cables and wiring harnesses 0 08 mm2 c of cross sectional area not less than 1 00 mm for single wires not incorporated into a harness or extending from the harness more than 250 mm Conductors of other materials shall be selected and sized to give equivalent performance 5 4 4 Fuel leakage Wiring and electrical components shall be designed placed or protected to minimize hazards arising from leakage from the fuel system such as contamination and fire 5 4 5 Mechanical protection Where wiring passes through metal parts of the frame or enclosures the holes shall be fitted with insulating bushes or the wiring protected by some other equivalent means 5 4 6 Wiring that flexes Wiring that flexes during normal operation of the truck
18. xes Identification Protection against electric shock 6 Information for use Electrical diagram 6 2 Safety checks Annex ZA informative Clauses of this European Standard addressing essential requirements or other provisions of EU Directives 6 aAaarh bh AR EPP PPR Ow WwW Ww PD TA TA A AAA A ATN A BSI 1998 Copyright European Committee for Standardization Provided by IHS under license with CEN No reproduction or networking permitted without license from IHS Not for Resale STD BSI BS EN 11 75 2 ENGL 1998 MM 16424469 0498290 910 EE 0 Introduction This European Standard is a type C standard as stated in EN 292 1 This standard has been prepared to be a harmonized standard to provide one means of conforming with the electrical aspects of the Essential Safety Requirements of the Machinery Directive and associated EFTA Regulations Electrical installations complying with this standard are deemed to satisfy these requirements The extent to which hazards are covered is indicated in the scope of this standard In addition machinery should comply as appropriate with EN 292 for hazards which are not covered by this standard 1 Scope 1 1 This standard specifies the electrical and related mechanical safety requirements for the design and construction of the electrical installation in internal combustion engine powered trucks hereinafter referred to as trucks with starter battery nominal voltages up to and including 24 V
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