Bsi bs en 01175 1 1998 + a1 2010

Licensed copy: University of Auckland Library, University of Auckland Library, Version correct as of 07/05/2012 14:08, (c) The British Standards Institution 2012

BRITISH STANDARD

Safety of industrial
trucks Ð Electrical
requirements Ð
Part 1: General requirements for battery
powered trucks

ICS 53.060

NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW

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BS EN
1175-1:1998
+A1:2010


Licensed copy: University of Auckland Library, University of Auckland Library, Version correct as of 07/05/2012 14:08, (c) The British Standards Institution 2012

BS EN 1175-1:1998+A1:2010

National foreword
This British Standard is the UK implementation of
EN 1175-1:1998+A1:2010. It supersedes BS EN 1175-1:1998, which is
withdrawn.
The start and finish of text introduced or altered by amendment is
indicated in the text by tags. Tags indicating changes to CEN text
carry the number of the CEN amendment. For example, text altered by
CEN amendment A1 is indicated by !".
The UK participation in its preparation was entrusted to Technical
Committee MHE/7, Industrial trucks.
A list of organizations represented on this committee can be obtained
on request to its secretary.
This publication does not purport to include all the necessary
provisions of a contract. Users are responsible for its correct
application.
Compliance with a British Standard cannot confer immunity
from legal obligations.

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 2011

ISBN 978 0 580 64228 9

Amendments/corrigenda issued since publication
Date

Comments

28 February 2011

Implementation of CEN amendment A1:2010


Licensed copy: University of Auckland Library, University of Auckland Library, Version correct as of 07/05/2012 14:08, (c) The British Standards Institution 2012

EUROPEAN STANDARD

EN 1175-1:1998+A1

NORME EUROPÉENNE
EUROPÄISCHE NORM

November 2010

ICS 53.060

Supersedes EN 1175-1:1998

English Version

Safety of industrial trucks - Electrical requirements - Part 1:
General requirements for battery powered trucks

Sécurité des chariots de manutention - Prescriptions
électriques - Partie 1: Prescriptions générales des chariots
alimentés par batterie

Sicherheit von Flurförderzeugen - Elektrische
Anforderungen - Teil 1: Allgemeine Anforderungen für
Flurförderzeuge mit batterieelektrischem Antrieb

This European Standard was approved by CEN on 23 November 1997 and includes Amendment 1 approved by CEN on 26 September
2010.
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 CEN Management Centre 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 CEN Management Centre has the same status as the
official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia,
Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland,
Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.

EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG

Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2010 CEN

All rights of exploitation in any form and by any means reserved
worldwide for CEN national Members.

Ref. No. EN 1175-1:1998+A1:2010: E


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

Contents

Page

Foreword ..............................................................................................................................................................6 
0

Introduction ............................................................................................................................................8

1

Scope ......................................................................................................................................................8 

2

Normative references ............................................................................................................................9

3

Definitions ........................................................................................................................................... 10 

4

!List of significant hazards" ....................................................................................................... 11

5
5.1
5.1.1
5.1.2
5.1.3
5.2
5.3
5.4
5.5
5.6
5.7
5.7.1
5.7.2
5.7.3
5.7.4
5.8
5.8.1
5.8.2
5.9
5.9.1
5.9.2
5.9.3
5.9.4
5.9.5
5.9.6
5.9.7

5.9.8
5.9.9
5.9.10
5.9.11
5.10
5.10.1
5.10.2
5.10.3
5.11
5.11.1
5.11.2
5.11.3
5.11.4
5.11.5
5.12
5.12.1
5.12.2

General requirements ......................................................................................................................... 15 
Traction battery ................................................................................................................................... 15 
Installation and protection ................................................................................................................. 15
Constraining ........................................................................................................................................ 16 
Disconnection ..................................................................................................................................... 16 
Battery connectors ............................................................................................................................. 16 
Heat dissipating electrical components ........................................................................................... 16
Electric motors .................................................................................................................................... 16 
Contactors ........................................................................................................................................... 16 
Electro-mechanical brakes ................................................................................................................ 16 
Protection against electric shock ..................................................................................................... 16 
Direct contact ...................................................................................................................................... 16 

Indirect contact ................................................................................................................................... 17 
Connection to the frame .................................................................................................................... 17
On-board chargers.............................................................................................................................. 17 
Protection of electrical equipment .................................................................................................... 17
Short circuits and overloads ............................................................................................................. 17
Overcurrent protective devices ......................................................................................................... 17 
Safety related control systems.......................................................................................................... 17 
Low voltage ......................................................................................................................................... 17 
Frame faults......................................................................................................................................... 18 
Travel control ...................................................................................................................................... 18 
Pulse control travel systems ............................................................................................................. 18 
Prevention of travel ............................................................................................................................ 18 
Steering control .................................................................................................................................. 18 
Load handling control ........................................................................................................................ 18
Tiller control ........................................................................................................................................ 18 
Speed limitation .................................................................................................................................. 19 
Slack wire-ropes or chains ................................................................................................................ 19 
!Parameter" .................................................................................................................................. 19 
Conductors .......................................................................................................................................... 19 
Protection ............................................................................................................................................ 19 
Cross-sectional area .......................................................................................................................... 19 
Specification ........................................................................................................................................ 20 
Wiring practices .................................................................................................................................. 20 
Multicore cables .................................................................................................................................. 20 
Main current cables ............................................................................................................................ 20 
Wiring that flexes ................................................................................................................................ 20 
Mechanical protection ........................................................................................................................ 20 
Identification........................................................................................................................................ 20 
Battery charging ................................................................................................................................. 20 
Movement during charging ................................................................................................................ 20

Charger switching............................................................................................................................... 21 

2


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

5.13
5.13.1
5.13.2
5.14
5.14.1
5.14.2
5.14.3
5.15
5.15.1
5.15.2
5.15.3
5.16
5.16.1
5.16.2

Emergency switching off .................................................................................................................... 21 
Access .................................................................................................................................................. 21 
Function................................................................................................................................................ 21 
Dielectric test (type test) ..................................................................................................................... 21 
Performance ......................................................................................................................................... 21 

Test voltage .......................................................................................................................................... 21 
Electronic components ....................................................................................................................... 22 
Insulation resistance test (routine test) ............................................................................................ 22
Test voltage .......................................................................................................................................... 22 
Insulation resistance of truck ............................................................................................................ 22
Insulation resistance of battery ......................................................................................................... 22
!Electromagnetic radiations ........................................................................................................... 22 
Non ionising radiations....................................................................................................................... 22
Electromagnetic compatibility" ...................................................................................................... 22

6
6.1
6.1.1
6.1.2
6.1.3
6.1.4
6.2
6.2.1
6.2.2
6.3
6.3.1
6.3.2
6.3.3
6.3.4
6.4
6.5
6.5.1
6.5.2
6.5.3

Additional requirements for nominal voltages in excess of 120 V................................................. 23
Battery .................................................................................................................................................. 23 
Container .............................................................................................................................................. 23 
Terminals and connectors .................................................................................................................. 23 
Poles ..................................................................................................................................................... 23 
Cover..................................................................................................................................................... 23
Battery connectors .............................................................................................................................. 23 
Requirements ....................................................................................................................................... 23 
Emergency disconnection .................................................................................................................. 23
Protection against electric shock ...................................................................................................... 23 
Electrical enclosures........................................................................................................................... 23 
Circuits ................................................................................................................................................. 24 
Bonding ................................................................................................................................................ 24 
Detection of frame faults .................................................................................................................... 24
Emergency switching off .................................................................................................................... 24
Insulation resistance test (routine test) ............................................................................................ 24
Test voltage .......................................................................................................................................... 24 
Insulation resistance of truck ............................................................................................................ 24
Insulation resistance of battery ......................................................................................................... 24

7
7.1
7.2
7.3
7.4
7.5

Information for use .............................................................................................................................. 24
Electrical diagram ................................................................................................................................ 25 
Safety checks ....................................................................................................................................... 25 

Battery .................................................................................................................................................. 25 
Minimum marking ................................................................................................................................ 25 
!Non-ionising radiation" .............................................................................................................. 25

Annex A (normative) Connectors for traction batteries ............................................................................... 26
A.1
Normative references .......................................................................................................................... 26
A.2
Definitions ............................................................................................................................................ 26
A.3
Requirements ....................................................................................................................................... 27
A.3.1 Mounting bracket ................................................................................................................................. 27 
A.3.2 Physical properties ............................................................................................................................. 27 
A.3.3 Contacts ............................................................................................................................................... 27 
A.3.4 Rated current ....................................................................................................................................... 27 
A.3.5 Polarity reversing ................................................................................................................................ 27 
A.3.6 Contacts with connector casing ........................................................................................................ 27 
A.3.7 Temperature resistance ...................................................................................................................... 27 
A.3.8 Enclosure protection........................................................................................................................... 27 
A.3.9 Protection of half-connector fitted to the battery ............................................................................ 27 
A.3.10 Coding .................................................................................................................................................. 28 
A.3.11 Cable sections ..................................................................................................................................... 28 
A.3.12 Locking of half-connectors ................................................................................................................ 28
A.4
Type-test methods ............................................................................................................................... 28 
A.4.1 Coding test ........................................................................................................................................... 28
A.4.2 Samples ................................................................................................................................................ 28 

3

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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

A.4.3
A.4.4
A.4.5
A.4.6
A.4.7
A.4.8
A.4.9
A.4.10
A.4.11
A.5
A.6

Preconditioning................................................................................................................................... 28
Temperature rise test ......................................................................................................................... 28 
Low temperature test ......................................................................................................................... 29 
Mechanical life test ............................................................................................................................. 29 
Sequential treatment for drop test .................................................................................................... 29
Drop test .............................................................................................................................................. 29 
Dielectric test ...................................................................................................................................... 30 
Test of disconnection in overload conditions for range 1 only ..................................................... 30 
Test of disconnection under emergency conditions for range 1 only .......................................... 30 
Maintenance of quality ....................................................................................................................... 30
Information for use ............................................................................................................................. 32

Annex B (normative) Electric motors - Output and test rules ..................................................................... 33
B.1
Normative references ......................................................................................................................... 33
B.2
Definitions ........................................................................................................................................... 33
B.3
Classification of enclosure and cooling ........................................................................................... 34
B.3.1 Protection ............................................................................................................................................ 34
B.3.2 Cooling ................................................................................................................................................. 34
B.4
Requirements ...................................................................................................................................... 35
B.4.1 Rated output ........................................................................................................................................ 35
B.4.2 Classes of insulation .......................................................................................................................... 35
B.4.3 Rated output test ................................................................................................................................ 35
B.4.4 Characteristic curves ......................................................................................................................... 36 
B.4.5 Tolerances on characteristic curves ................................................................................................ 36 
B.4.6 Overspeed test .................................................................................................................................... 37 
B.4.7 Dielectric test ...................................................................................................................................... 37 
B.4.8 Terminal markings .............................................................................................................................. 37 
B.4.9 Markings – Identification .................................................................................................................... 38 
B.5
Testing ................................................................................................................................................. 38 
B.5.1 General ................................................................................................................................................. 38 
B.5.2 Type tests ............................................................................................................................................ 38 
B.5.3 Routine tests ....................................................................................................................................... 39 
Annex C (normative) Electromagnetic contactors ....................................................................................... 40
C.1
Definitions ........................................................................................................................................... 40
C.2
Nominal service conditions ............................................................................................................... 40

C.2.1 Climatic conditions ............................................................................................................................. 40
C.2.2 Voltage ................................................................................................................................................. 40
C.3
Types of contactor .............................................................................................................................. 40
C.3.1 Type A .................................................................................................................................................. 41
C.3.2 Type B .................................................................................................................................................. 41
C.3.3 Type C .................................................................................................................................................. 41
C.3.4 Type D .................................................................................................................................................. 41
C.4
General requirements ......................................................................................................................... 41
C.4.1 Limits of operation.............................................................................................................................. 41
C.4.2 Mechanical durability ......................................................................................................................... 42
C.5
Type tests ............................................................................................................................................ 42
C.5.1 Temperature rise test of main circuit ............................................................................................... 42
C.5.2 Temperature rise tests of operating coils ........................................................................................ 43
C.5.3 Dielectric tests .................................................................................................................................... 44
C.5.4 Verification of operating limits .......................................................................................................... 44
C.5.5 Verification of making and breaking capacities in proving operation .......................................... 45
C.5.6 Verification of rated making and breaking capacities of intermittently rated contactors of
table C.6 category 2 ............................................................................................................................ 45 
C.5.7 Verification of mechanical durability ................................................................................................ 46
C.6
Routine test ......................................................................................................................................... 46 
C.6.1 Operating limits................................................................................................................................... 46 
C.6.2 Dielectric test ...................................................................................................................................... 46 
C.7
Marking ................................................................................................................................................ 46 

4

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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

Annex ZA (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC" .................................................................................. 47

5


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

Foreword
This document (EN 1175-1:1998+A1:2010) 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 May 2011, and conflicting national standards shall be withdrawn at the
latest by May 2011.
!This document 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).
For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document."
This document includes Amendment 1, approved by CEN on 2010-09-26.
This document supersedes EN 1175-1:1998.
!The main changes compared to the previous version are:



modification of Annex ZA;



minor technical changes in 5.9.4 to 5.9.11 and 7.3;



reference to EN 292-1 be replaced with EN ISO 12100-1:2003, EN 292-2 be replaced with
EN ISO 12100-2:2003 and EN 954-1 be replaced with EN ISO 13849-1:2008;



addition of requirements for radiation and software parameter."

!deleted text"
The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ".
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
This European Standard is one of a package of standards for the safety of industrial trucks:
!prEN ISO 3691-1, Industrial trucks — Safety requirements and verification — Part 1: Self-propelled
industrial trucks, other than driverless trucks, variable-reach trucks and burden-carrier trucks (ISO/DIS 36911:2008)"
!EN 1726-2"

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 Part 2: Additional requirements for trucks with elevating operator position and trucks
specially designed to travel with elevated load

!EN 1551"

Safety of industrial trucks - Self propelled trucks over 10 000 kg capacity

!EN 1459"

Safety of industrial trucks - !Self propelled variable" reach trucks

!EN ISO 3691-5, Industrial trucks — Safety requirements and verification — Part 5: Pedestrian-propelled
trucks (ISO 3691-5:2009)"

6


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

!deleted text"
!EN 1757-3"

Safety of industrial trucks - Pedestrial controlled manual and semi manual trucks Part 3: Platform trucks

!deleted text"
EN 1525

Safety of industrial trucks - Driverless 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 of industrial trucks - Additional requirements for automated functions on trucks

!EN 1755"

Safety of !industrial" trucks - Operation in potentially explosive atmospheres; Use
in flammable gas, vapour, mist and dust

!EN 12053"

Safety of industrial trucks - Test methods for measuring noise !emissions"

prEN ISO/DIS 13564 Test method for measuring visibility from self-propelled trucks
(ISO/DIS 13564:1996)
!EN 13059"

Safety of industrial trucks - Test methods for measuring vibration

!EN 12895"

Industrial trucks - Electromagnetic compatibility

!deleted text"
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following
countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech
Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain,
Sweden, Switzerland and United Kingdom.

7


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

0

Introduction

!This European Standard is a type C standard as stated in EN ISO 12100-1:2003." 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 ISO 12100-2:2003 for hazards which are not covered by this European
Standard."

1

Scope

1.1 This standard specifies electrical and related mechanical safety requirements for design and
construction of the electrical installation in battery powered industrial trucks hereinafter referred to as trucks,
with nominal voltages of the truck system up to 240 V. The Annex A is normative and gives requirements for
”Connectors for traction batteries”. Annex B is normative and contains ”Electric motors - Output and test rules”
and Annex C is normative and contains ”Electromagnetic contactors”.
NOTE 1
Reference is made to this standard in other standards which cover the non-electrical requirements of the
various industrial truck types.
NOTE 2
This standard does not address the subject of charging of traction batteries (CENELEC TC 21X is preparing
safety standards for battery charging).
!deleted text"
!NOTE 3 The special requirements for operation in potentially explosive atmospheres are not covered in this European
Standard."

1.2 The requirements of this standard are applicable, when trucks are operated under the following climatic
conditions:


Average ambient temperature for continuous duty:

+25°C;



Maximum ambient temperature, short term (up to 1 h):

+40°C;



Lowest ambient temperature for trucks intended for use in normal indoor conditions:

+5 °C;



Lowest ambient temperature for trucks intended for use in normal outdoor conditions:

-20 °C;



Altitude:



Relative humidity:

up to 2000 m;
in the range 30 % to 95 % (non condensing).

1.3 This standard covers specific hazards (listed in clause 4), which could occur during the intended use of
trucks. !For hazards occurring during construction, transportation, commissioning, decommissioning and
disposal, reference should be made to EN ISO 12100-2:2003."

8


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

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.
!deleted text"
EN 563:1994

Safety of machinery - Temperatures of touchable surfaces - Ergonomic data to
establish temperature limit values for hot surfaces

!deleted text"
EN 1050:1996

Safety of machinery - Priciples for risk assessment

!EN 12895:2000, Industrial trucks — Electromagnetic compatibility"
EN 60034-1:1995

Rotating electrical machines
Part 1: Rating and performance (IEC 34-1:1994, modified)

EN 60204-1:1992

Safety of machinery - Electrical equipment of machines
)
Part 1: General requirements (IEC 204-1:1992, modified)1

EN 60529:1991

Degrees of protection provided by enclosures (IP Code) (IEC 529:1989)

EN 60947-3:1992

Low-voltage switchgear and controlgear
Part 3: Switches, disconnectors, switch-disconnectors and fuse-combination units
(IEC 947-3:1990, modified + Corrigendum December 1991)

EN 60947-5-1:1991

Low-voltage switchgear and controlgear
Part 5: Control circuit devices and switching elements
Section one: Electromechanical control circuit devices (IEC 947-5-1:1990)

HD 53.6 S2:1992

Rotating electrical machines;
Part 6: Methods of cooling (IC Code) (IEC 34-6:1991)

HD 53.8 S4:1993

Rotating electrical machines;
Part 8: Terminal markings and direction of rotation of rotating machines
(IEC 34-8:1972 + A1:1990, modified)

HD 405.1 S1

Tests on electric cables under fire conditions. Part 1 : Test on a single vertical
insulated wire or cable

!EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1:
Basic terminology, methodology (ISO 12100-1:2003)
EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2:
Technical principles (ISO 12100-2:2003)
EN ISO 13849-1:2008, Safety of machinery — Safety-related parts of control systems — Part 1: General
principles for design (ISO 13849-1:2006)"
IEC 85:1984

Thermal evaluation and classification of electrical insulation

1 ) This standard applies only in parts (option 3). Specific clauses have been indicated in the text.

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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

IEC 384-14:1993

Fixed capacitors for use in electronic equipment. Part 14: Sectional specification:
Fixed capacitors for electromagnetic interference suppression and connection to the
supply mains

ISO 5053:1987

Powered industrial trucks - Terminology

ISO 6743-4:1982

Lubricants, industrial oils and related products (class L).
Classification - Part 4: Family H (Hydraulic systems)

3

Definitions

For the purposes of this standard, definitions given in ISO 5053:1987 apply together with the following:
3.1
nominal voltage (of the truck system)
the total number of battery cells connected in series in the truck system multiplied by 2 V for lead acid
batteries and by 1,2 V for alkaline batteries

3.2
truck type test
one-off test to verify compliance with this standard for each truck type.
3.3
truck routine test
repetitive test required for all production trucks.
3.4
nominal current
current in amperes that the connector is able to carry continuously without exceeding the allowable
temperature indicated in A.3.7
3.5
emergency breaking current
current in amperes specified in A.4.11 that the connector shall be able to break in the case of exceptional
circumstance or hazard.
3.6
motor type test
a test made on one or more items of electrical equipment of a new design or of a new manufacture to
demonstrate that it complies with this standard.
3.7
motor routine test
a test to which the electrical equipment on an order is subjected to prove its soundness. This can be reduced
by agreement to testing a percentage of a production batch.
3.8
maximum service rotational frequency (speed) of a motor
the highest rotational frequency assigned to the machine by the manufacturer.

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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

3.9
rated motor voltage
rated voltage is equal to the nominal voltage of the vehicle battery, i.e. the maximum number of cells which
are connected in series multiplied by the nominal voltage of each cell, which for lead acid cells is 2,0 V and
1,2 V for conventional alkaline batteries.
3.10
rated motor output
the output in kW at the shaft of an electric motor as agreed by the manufacturer under the associated
conditions (e g rotational frequency, rated voltage and current).
3.11
continuous rated motor output
The rated output assigned by the manufacturer that can be sustained indefinitely on test without exceeding
the temperature rises specified in table B.1
3.12
one hour rated motor output
the rated output assigned by the manufacturer that can be sustained for one hour, starting from normal
ambient temperature without exceeding the temperature rises specified in table B.1
3.13
short time rated motor output
the rated output assigned by the manufacturer that can be sustained for a specified period starting from the
normal ambient temperature without exceeding the temperature rises specified in table B.1
3.14
duty type motor rating
the time for a duty cycle is 10 min and the cyclic duration factor is expressed as a percentage that can be
sustained, starting from the normal ambient temperature without exceeding the temperature rise specified in
table B.1

4

!List of significant 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
requirements are designed to limit the risk or remove the hazard in each situation.

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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

Table 1 — List of hazards
Hazard
4.1

Mechanical hazards (1)

4.1.1

Crushing hazard (1.1)

5.1.2

Constraining

- between truck components

5.6

Electro-mechanical brakes

- between truck & obstacles

5.9.3

Travel control system

Impact by collision (20)

5.9.4

Pulse control travel system

4.1.2.1 - when driven by the operator

5.9.8

Tiller control

4.1.3

Loss of stability (18)

5.9.9

Speed limitation

- from excess speed

5.9.10

Slack wire-ropes or chains

- from faulty battery mass

7.4

Battery

4.2

Electrical hazards (2)

5.1.1.1

Covers

4.2.1

electric shock (2.1)

5.1.1.2

Design of covers

4.2.2

short circuit

5.1.3

Disconnection

4.2.3

overloading

5.2

Battery connectors

- all voltages

5.4

Electric motors

5.5

Contactors

5.7.1

Direct contact

5.7.2

Indirect contact

5.7.3

Connection to the frame

5.7.4

On-board chargers

5.8

Protection of electrical equipment

5.10.1

Protection

5.10.2

Cross-sectional area

5.11.1

Multicore cables

5.11.2

Main current cables

5.11.3

Wiring that flexes

5.11.4

Protection

5.12.1

Movement during charging

4.1.2

12

Corresponding requirements


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

120 V < voltages ≤ 240 V

4.3

Thermal hazards (3)

5.12.2

Charger switching

5.14

Dielectric test

5.15

Insulation resistance test

6.1.1

Battery

6.1.2

Terminals and connectors

6.1.3

Poles

6.1.4

Cover

6.2

Battery connectors

6.3.1

Electrical enclosures

6.3.2

Circuits

6.3.3

Bonding

6.3.4

Detection of frame faults

6.5

Insulation resistance test

7.4

Minimum marking

5.3

Heat
dissipating
components

electrical

13


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

Hazard

Corresponding requirements

4.4

Hazards generated by substances (7)

5.1.1.3

Sparking components

4.4.1

Battery electrolyte

5.1.1.4

Ventilation

4.4.2

Fire or explosion hazard (7.2)

5.1.1.5

Internal surface

5.2

Battery connectors

7.3

Battery

6.1.3

Poles

6.2.1

Requirements

6.2.2

Emergency disconnection

6.4

Emergency switching off

6.5

Insulation resistance test

5.11.5

Identification

!5.9.11

Parameter"

!7.5

Non ionising radiation"

- all voltages
!- battery charging"

120 V > voltages ≤ 240 V

4.5

Ergonomic hazards (8)

4.5.1

Human error (8.6)

4.5.1.1

14

- when the truck is serviced

4.6

Hazards due to functional disorders
(10)

4.6.1

failure of energy supply

4.6.2

failure of control system

4.6.3

loss of machine stability

7.1

Electrical diagram

7.2

Safety checks

7.3

Battery

7.4

Minimum marking

5.4

Electric motors

5.5

Contactors

5.9.1

Low voltage

5.9.2

Frame faults

5.9.3

Travel control system

5.9.4

Pulse control travel system

5.9.5

Prevention of travel

5.9.6

Steering control

5.9.7

Load handling control


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

5.9.9
!5.9.11

Parameter"

5.10.3

Specification

5.13

Emergency switching off

6.4

Emergency switching off

!Programming errors

5.9.11

Parameter"

!Electromagnetic radiation

5.16.1

Non ionising radiation

5.16.2

5

Speed limitation

Electromagnetic compatibility"

General requirements

5.1 Traction battery
This clause specifies the safety requirements for lead acid and alkaline (nickel cadmium or nickel iron) type of
batteries when the truck is used as intended by the manufacturer.
NOTE

5.1.1
5.1.1.1

For other types of batteries special requirements can be necessary.

Installation and protection
Covers

Battery shall be covered. Metal covers shall be designed to provide an air space of at least 30 mm above the
live parts of the battery. Alternatively the air space may be reduced to a minimum of 10 mm provided covers
or live parts of the battery are insulated in such a manner that disintegration and/or displacement of the
insulation is prevented.
5.1.1.2

Design of covers

The cover(s) shall be so constructed that no force is transmitted to or contact made with the battery cells or
connectors when a force of 980 N is applied to the cover(s) over any area 300 mm x 300 mm. The cover(s)
shall be fitted in such a way as to prevent unintentional displacement.

5.1.1.3

Sparking components

Sparking components which can reach a temperature of 300°C or more shall not be located where explosive
gas/air mixtures can be present. Battery connectors shall be accepted as non-sparking components provided
they are not used as an emergency switching-off device, see 5.13.2 a).
5.1.1.4

Ventilation

Suitable ventilation openings shall be provided in the battery container, compartment or cover so that
dangerous accumulations of gases do not occur when the equipment is used in accordance with
manufacturer's instructions.

15


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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

NOTE
Experience has indicated, when openings are positioned such that gases can escape freely, ventilation
openings are usually satisfactory if they provide a cross section in square millimetres equal to half the number of cells,
multiplied by the 5 h rated capacity in amperes hour. This level of ventilation is however not intended to cover the charging
condition.

5.1.1.5

Internal surface

The finish of internal surfaces of battery containers shall be resistant to the chemical effects of the electrolyte.
Provision shall be made to prevent the discharge of electrolyte to the ground.
5.1.2

Constraining

Batteries and containers of all trucks shall be constrained to prevent displacement which gives rise to danger.
On rider trucks means shall be provided so that in the event of 90° tipover of the truck the battery assembly
will be constrained, so as to avoid the risk of injury to the operator which could occur by the battery being
displaced.
5.1.3

Disconnection

Provision shall be made to disconnect the battery/batteries to facilitate maintenance and replacement.

5.2 Battery connectors
The connectors used for connecting the traction batteries to the equipment of battery operated industrial
trucks and to the charging equipment shall comply with the requirements in Annex A.

5.3 Heat dissipating electrical components
Such electrical components shall be located and arranged so as to avoid overheating and subsequent injury
to personnel, taking into account the requirements of EN 563 : 1994 and damage to adjacent parts of the
truck.

5.4 Electric motors
Direct current motors shall comply with Annex B.

5.5 Contactors
Direct current contactors shall comply with Annex C.

5.6 Electro-mechanical brakes
Where electro-mechanical brakes are fitted these shall be mechanically applied and electrically released to
ensure that braking facility is retained in case of failure in the electrical power source.
NOTE

For other brake requirements, see specific truck safety standards.

5.7 Protection against electric shock
5.7.1

Direct contact

In the operating conditions of the truck the uninsulated live parts shall be protected to a degree of IPxxB
preventing direct contact. For top surfaces, however, the minimum degree of protection shall be IPxxD. See
EN 60529:1991.

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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

5.7.2

Indirect contact

Protection against indirect contact shall be achieved by electric separation in accordance with 6.3.3 of
EN 60204-1:1992.
5.7.3

Connection to the frame

There shall be no electrical connection to the truck frame, with the exception of:
a)

frame fault detection system;

b)

lighting and ancillary equipment, providing its input voltage does not exceed 24 V (nominal) and it is
galvanically separated from the main power source, see 6.4 of EN 60204-1:1992;

c)

earthing during charging when using on-board chargers, see 5.7.4;

d)

suppression capacitors, minimum standard Class Y in IEC 384-14:1993;

e)

the screen of screened cables and components. This condition shall meet the requirements of 5.14.

5.7.4

On-board chargers

When trucks are fitted with on-board chargers the requirements in 6.3 up to and including 6.3.2, 7.2.1 and 8
up to and including 8.2 of EN 60204-1:1992, shall apply. The enclosure containing equipment connected to
the mains supply shall be IPxxB of EN 60529:1991. However, for top surfaces the degree of protection shall
be at least IPxxD.

5.8 Protection of electrical equipment
5.8.1

Short circuits and overloads

Motor circuits related to truck travel, load movements, and steering shall be protected against short circuit
conditions. Control and auxiliary circuits shall be protected against short circuit conditions and overload
conditions. Several auxiliary circuits in parallel, with combined rated current not exceeding 12 A, can be
protected by a single device.
NOTE
Further information regarding location of overcurrent protective devices can be found in 7.2.7 of
EN 60204-1:1992.

5.8.2

Overcurrent protective devices

The overcurrent protective devices shall be capable of interrupting the maximum fault current that can occur in
the circuit and shall be protected by their construction or their installation so that they provide no fire hazard.
7.2.8 of EN 60204-1:1992, and the following shall apply:


The rated current of fuses or the setting of other overcurrent protective devices shall be selected as low
as possible but adequate for the overcurrent due. (e.g. to motor starting or switching of transformers).

The rating of these devices shall be indicated on the electrical diagram.

5.9 Safety related control systems
5.9.1

Low voltage

Electrical systems shall be so designed that all functions operate and safety is not jeopardized if the voltage
should fall to 0,70 of the nominal voltage with the exception of class 1 contactors in accordance with Annex C.

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BS EN 1175-1:1998+A1:2010
EN 1175-1:1998+A1:2010 (E)

If there is a risk due to voltages lower than this level, then the control system shall prevent operation of the
relevant function of the truck.
5.9.2

Frame faults

The electric circuits shall be so designed or protected, that frame faults shall not cause inadvertent
movements that cannot be controlled by the driver.

5.9.3

Travel control

The travel control shall be so arranged that on level ground the truck will start from rest only when the
control(s) for speed and direction are activated. Where no neutral position of the direction control is provided
the truck shall not move unless the speed control device is actuated.
5.9.4

Pulse control travel systems

Any uncontrolled full power travel conditions due to a fault in the electronic power switching circuit shall be
terminated within 0,2 s. It shall be possible to check the operation of this system at service intervals in
accordance with the manufacturer's instructions. The safety related parts shall be in accordance with category
1 !in EN ISO 13849-1:2008, 6.2."
5.9.5

Prevention of travel

A separate device independent of the speed control device (accelerator) shall automatically prevent operation
of the travel circuit when the operator leaves the truck, e.g. seat switch, pedestrian tiller switch. Where
separate travel controls remote from the driving position are provided, the device can be overridden when this
system is selected. Control circuits shall comply at least with !category 1 in EN ISO 13849-1:2008, 6.2."
Spurious tripping of the device as a result of operating conditions, such as rough ground, shall be prevented,
e.g. by incorporating a time delay in a seat switch.
NOTE
The time delay in any seat switch should not be excessively long in order to minimise the possibility of the
truck controls remaining active while the operator is dismounting.

5.9.6

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 single 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 manufacturers instruction. The safety related parts shall be in
accordance with category 3 !in EN ISO 13849-1:2008, 6.2."
5.9.7

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 ISO 13849-1:2008, 6.2."
This requirement is not necessary where the movements are controlled by some other means, e.g. manually
operated hydraulic valves.
5.9.8

Tiller control

The tiller of self-propelled pedestrian-controlled trucks shall incorporate a device to energize the direction of
travel away from the driver until pressure on the device is relieved or stop the truck by applying the brakes,

18