Bsi bs en 01175 3 1998 + a1 2010

Licensed copy: University of Auckland Library, University of Auckland Library, Version correct as of 07/05/2012 14:09, (c) The British Standards Institution 2012

BRITISH STANDARD

Safety of industrial trucks Ð
Electrical requirements Ð
Part 3: Specific requirements for the
electric power transmission systems of
internal combustion engine powered
trucks

ICS 53.060

NO COPYING WITHOUT BSI PERMISSION EXCEPT AS PERMITTED BY COPYRIGHT LAW

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BS EN
1175-3:1998
+A1:2010


Licensed copy: University of Auckland Library, University of Auckland Library, Version correct as of 07/05/2012 14:09, (c) The British Standards Institution 2012

BS EN 1175-3:1998+A1:2010

National foreword
This British Standard is the UK implementation of
EN 1175-3:1998+A1:2010. It supersedes BS EN 1175-3:1998, 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withdrawn.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 64230 2

Amendments/corrigenda issued since publication
Date

Comments

31 January 2011

Implementation of CEN amendment A1:2010


Licensed copy: University of Auckland Library, University of Auckland Library, Version correct as of 07/05/2012 14:09, (c) The British Standards Institution 2012

EUROPEAN STANDARD

EN 1175-3:1998+A1

NORME EUROPÉENNE
EUROPÄISCHE NORM

November 2010

ICS 53.060

Supersedes EN 1175-3:1998

English Version

Safety of industrial trucks - Electrical requirements - Part 3:

Specific requirements for the electric power transmission
systems of internal combustion engine powered trucks
Sécurité des chariots de manutention - Prescriptions
électriques - Partie 3: Prescriptions particulières des
systèmes à transmission électrique des chariots équipés
d'un moteur thermique

Sicherheit von Flurförderzeugen - Elektrische
Anforderungen - Teil 3: Besondere Anforderungen für
elektrische Kraftübertragungssysteme von
Flurförderzeugen mit Verbrennungsmotoren

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 1175-3:1998+A1:2010: E


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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

Contents

Page

Foreword ..............................................................................................................................................................4 
0

Introduction ............................................................................................................................................6

1

Scope ......................................................................................................................................................6 

2

Normative references ............................................................................................................................6

3

Definitions ..............................................................................................................................................7 

4

!List of significant hazards" ..........................................................................................................8

5
5.1
5.1.1
5.1.2
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5
5.3
5.3.1
5.3.2
5.3.3
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.5
5.5.1

5.5.2
5.5.3
5.5.4
5.5.5
5.5.6
5.5.7
5.5.8
5.5.9
5.6
5.6.1
5.6.2
5.6.3
5.6.4
5.6.5
5.7
5.7.1
5.7.2
5.7.3
5.8
5.8.1
5.8.2

General requirements ......................................................................................................................... 10 
Contactors ........................................................................................................................................... 10 
D.c. contactors ≤ 240 V ...................................................................................................................... 10 
Other contactors ................................................................................................................................. 10 
Electric machines ............................................................................................................................... 10 
D.c. motors ≤ 240 V ............................................................................................................................. 10 
D.c. generators ≤ 240 V ...................................................................................................................... 10 
Other machines ................................................................................................................................... 10 

Protection ............................................................................................................................................ 10 
Cooling ................................................................................................................................................. 10 
Protection of electrical equipment .................................................................................................... 11
Short circuit and overload ................................................................................................................. 11
Overcurrent protective device ........................................................................................................... 11 
Installation ........................................................................................................................................... 11 
Safety related control systems.......................................................................................................... 11 
Frame faults......................................................................................................................................... 11 
Travel control ...................................................................................................................................... 11 
Electronic travel control system ....................................................................................................... 11 
Speed limitation .................................................................................................................................. 11 
!Parameter" .................................................................................................................................. 12 
Wiring practices, conductors and electrical components ............................................................. 12
Thermal and mechanical damage ..................................................................................................... 12 
Fuel leakage ........................................................................................................................................ 12 
Protection ............................................................................................................................................ 12 
Cross-sectional area .......................................................................................................................... 12 
Main current cables ............................................................................................................................ 12 
Wiring that flexes ................................................................................................................................ 12 
External copper conductors .............................................................................................................. 12
Identification........................................................................................................................................ 13
Multicore cables .................................................................................................................................. 13 
Protection against electric shock ..................................................................................................... 13 
Electrical enclosures .......................................................................................................................... 13 
Indirect contact ................................................................................................................................... 13 
Connection to the frame .................................................................................................................... 13
Control and auxiliary circuits ............................................................................................................ 13
Equipotential bonding ........................................................................................................................ 13
Dielectric test (type test) .................................................................................................................... 14 
Performance ........................................................................................................................................ 14 

Electronic components ...................................................................................................................... 14 
Test voltage ......................................................................................................................................... 14 
Insulation resistance test (routine test)............................................................................................ 14
Test voltage ......................................................................................................................................... 14 
Insulation resistance of truck ............................................................................................................ 14

2


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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

5.9
5.9.1
5.9.2

!Electromagnetic radiations ........................................................................................................... 14 
Non ionising radiations....................................................................................................................... 14
Electromagnetic compatibility" ...................................................................................................... 14

6
6.1
6.2
6.3
6.4

Information for use .............................................................................................................................. 15
Electrical diagram ................................................................................................................................ 15 

Safety checks ....................................................................................................................................... 15 
Minimum marking ................................................................................................................................ 15 
!Non-ionising radiation" .............................................................................................................. 15

Annex A (normative) Generators - Output and test rules ............................................................................. 16
A.1
Normative references .......................................................................................................................... 16
A.2
Definitions ............................................................................................................................................ 16
A.3
Requirements ....................................................................................................................................... 17
A.3.1 Characteristic curves .......................................................................................................................... 17 
A.3.2 Tolerances on characteristic curves ................................................................................................. 17 
A.4
Testing .................................................................................................................................................. 17 
A.4.1 Type tests ............................................................................................................................................. 17 
A.4.2 Routine tests ........................................................................................................................................ 17 
Annex ZA (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC" .................................................................................. 19

3


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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

Foreword
This document (EN 1175-3:1998+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."
!deleted text"
This document includes Amendment 1, approved by CEN on 2010-09-26.
This document supersedes EN 1175-3:1998.
!The main changes compared to the previous version are:


modification of Annex ZA;



requirements for radiation and software parameters;



minor technical changes in 5.4.3 to 5.4.4 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."

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 3691-1:2008)"
!EN 1726-2"

Safety of 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 andtrucks 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)"

4


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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

!deleted text"
!EN 1757-3"
!Safety of industrial trucks - Pedestrian 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
!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.

5


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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+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 the safety requirements for the design and construction of electrical power
transmission systems of trucks with internal combustion engines driving one or more generators with outputs
up to and including 600 V supplying power to function motors. The Annex A is normative and contains
“Generators - Output and test rules”.
NOTE 1
Reference is made to this standard in other standards which cover the non-electrical requirements of the
various industrial truck types.
!deleted text"
!NOTE 2 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:


Maximum ambient temperature, continuous duty:

+40°C;



Lowest ambient temperature:

-20 °C;



Service altitude:



Relative humidity:

up to 2000 m;
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, decommissioning and disposal,
reference should be made to EN ISO 12100-2:2003."

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 1050:1996

Safety of machinery - Risk assessment

EN 1175-1:1998

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

6


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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

!EN 12895:2000, Industrial trucks — Electromagnetic compatibility"
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 60947-1:1991

Low-voltage switchgear and controlgear - Part 1: General rules
(IEC 947-1:1988, modified)

EN 60947-4-1:1992

Low-voltage switchgear and controlgear - Part 4: Contactors and motor-starters
Section one: Electromechanical contactors and motor-starters
(IEC 947-4-1:1990)

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)

!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 349:1991

Electric traction - Rotating electrical machines for rail and road vehicles

IEC 384-14:1993

Fixed capacitors for use in electronic equipment.
Part 14: Sectional specification: Fixed capacitors for electromagnetic interference

ISO 5053:1987

Powered industrial trucks – Terminology

3

Definitions

For the purposes of this standard, definitions given in ISO 5053 apply together with the following:
3.1
live part
a conductor or conductive part intended to be energized in normal use
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

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

7


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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

3.4
rated rotational frequency of generator
the frequency assigned by the manufacturer. This frequency is equivalent to the rated frequency of the
internal combustion engine, if the generator is directly coupled with the engine
3.5
rated voltage of generator
for the generator two rated voltages is assigned by the manufacturer in accordance with the continuous rated
output defined in A.2.3.1
3.6
rated generator output
the output in kW at the terminals of the generator assigned by the manufacturer
3.7
continuous rated output of generator
for the generator two continuous outputs are assigned. The first is determined by the temperature rise of the
windings carrying the load current (higher value of the load-current and lower voltage); the second is
determined by the temperature rise of the field windings at maximum excitation (lower value of the loadcurrent with higher voltage). Both continuous rated outputs correspond to points of the full-load characteristic
defined in A.3.1

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.
Table 1 — List of hazards
Hazard

Corresponding requirements

4.1
4.1.1
4.1.1.1
4.1.2

Mechanical hazards (1)
Impact by collision (1.6)
- when driven by the operator
Loss of stability (1.11)

5.4.1

Electrical circuit design

5.4.2

Travel control system

5.4.3

Electronic travel control system

5.4.4

Speed limitation devices

- from excess speed

8

4.2

Electrical hazards (2)

5.1

Contactors

4.2.1

Electric shock (2.1)

5.2

Electric machines (motors and generators)

4.2.2

Short circuit

5.3.1

Protection of circuits

4.2.3

Overloading

5.3.2

Overcurrent protective devices

5.5.1

Conductors, insulation

5.5.3

Cables, wiring

5.5.4

Conductors, cross-sectional area


Licensed copy: University of Auckland Library, University of Auckland Library, Version correct as of 07/05/2012 14:09, (c) The British Standards Institution 2012

BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

4.4

Hazards generated by substances (7)

!- battery charging"
4.4

Ergonomic hazards (8)

4.4.1

Human error (8.6)

5.5.5

Main current cables

5.5.6

Wiring that flexes

5.5.7

Cable specifications

5.5.9

Cable insulation

5.6.1

Degree of protection

5.6.2

Protection against indirect contact

5.6.3

Connecting to the frame

5.6.4

Maximum voltages

5.6.5

Equipotential bonding

5.7

Dielectric test

5.8

Insulation resistance test

5.3.3

Protection of electrical machines

5.5.2

Protection against fuel leakage

!7.3
5.5.8

4.5

- when the truck is serviced

Hazards due to functional disorders

Electrical circuit identification

!5.9.11 Parameter"
!7.5

4.4.1.1

Battery"

(10)

Non ionising radiation"

6.1

Electrical diagram

6.2

Safety checks

6.3

Minimum marking

5.1

Contactors

5.2

Electric machines

5.4.1

Electrical circuit design

5.4.2

Travel control

5.4.3

Electronic travel control system

5.4.4

Speed limitation

!5.4.5 Parameter"
5.5.6

Wiring that flexes

5.5.7

External copper conductors

9


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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

!Programming errors

5.4.5

!Electromagnetic radiation

5.9.1, 6.4 Non ionising radiation
5.9

5

Parameter"

Electromagnetic radiations"

General requirements

5.1 Contactors
5.1.1

D.c. contactors ≤ 240 V

Contactors for direct current (d.c.) voltages up to and including 240 V shall comply with Annex C of
EN 1175-1:1998.
5.1.2

Other contactors

All other contactors which break motor current under normal operation shall meet the requirements in
EN 60947-1:1991 and EN 60947-4-1:1992. For direct current (d.c.) application at least category DC 3 where
these are used for shunt-wound electric motors, category DC 5 where these are employed for series-wound
motors and at least category AC 3 for alternating current (a.c.) application, shall be applied.

5.2 Electric machines
5.2.1

D.c. motors ≤ 240 V

Motors with rated voltage up to and including 240 V shall comply with Annex B of EN 1175-1:1998.
5.2.2

D.c. generators ≤ 240 V

Generators with rated voltages up to and including 240 V shall comply with Annex A of this standard.
5.2.3

Other machines

D.c. and a.c. machines with rated voltage up to 600 V shall comply with IEC 349:1991. Deviating from this
specification maximum collector temperature rise of 120 K for class B insulation and 140 K for classes F and
H insulation are permitted.
5.2.4

Protection

The classification of enclosure shall be in accordance with EN 60529:1991 and shall be not less than IP 20.
NOTE

5.2.5

The level of protection can be achieved considering the contribution of mechanical parts e.g. gearbox.

Cooling

The classification of cooling methods shall be in accordance with HD 53.6 S2:1992.

10


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BS EN 1175-3:1998+A1:2010

EN 1175-3:1998+A1:2010 (E)

5.3 Protection of electrical equipment
5.3.1

Short circuit and overload

Control and auxiliary circuits shall be 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.
5.3.2

Overcurrent protective device

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.
See 7.2.8 of EN 60204-1:1992.
5.3.3

Installation

Electrical machines should be designed and installed in such a way that they are protected against foreign
material, humidity or mechanical damage such as to guarantee function and sufficient insulation. Protection
shall at least correspond to IP 23 in accordance with EN 60529:1991.

5.4 Safety related control systems
5.4.1

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.
5.4.2

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. 5.9.5 of EN 1175-1:1998 also applies.
5.4.3

Electronic travel control system

Electronic travel control systems shall be arranged so as to avoid inadvertent travel movements that cannot
be controlled by the driver. The safety related parts shall be in accordance with at least category 1 !in
EN ISO 13849-1:2008, 6.2."
5.4.4

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 an electrical fault,
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
manufacturers instruction;

The safety related parts shall be in accordance with category 2 !in EN ISO 13849-1:2008, 6.2."
b)

Mechanically operated switches shall be of positive opening type in accordance 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).

11


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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

5.4.5

!Parameter

Any uncontrolled change of the electronic system parameter shall maintain the safe operation and correct
function of the truck.
Any change of parameter values controlled by the operator shall not result in a hazardous situation. The
system shall ensure safe operation and correct function of the truck."

5.5 Wiring practices, conductors and electrical components
5.5.1

Thermal and mechanical damage

All conductors 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
operation condition.
5.5.2

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.
5.5.3

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.
NOTE

5.5.4

Further information regarding wiring can be found in clause 15 of EN 60204-1:1992.

Cross-sectional area

The cross-sectional area shall be so selected that during operation of the truck the temperature does not
exceed the temperature rating of insulation used.
5.5.5

Main current cables

The main current cables shall be single core resistant against mechanical damage, and not easily flammable.

5.5.6

Wiring that flexes

Wiring that flexes during normal operation of the truck functions shall be relieved of mechanical strain at their
electrical termination.
5.5.7

External copper conductors

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:

12

1)

for control wiring

0,50 mm²;

2)

for signal wiring

0,30 mm²;


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EN 1175-3:1998+A1:2010 (E)

3)
c)

for data communication wiring and for conductors of adequately supported copper multicore cables
and wiring harnesses
0,08 mm²
2

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.
5.5.8

Identification

Wires, cables, terminals etc shall be identified by codings in accordance with the electrical diagram included in
the service manual.
5.5.9

Multicore cables

Unless specially designed, multicore cables fed by circuits of different voltage shall have insulation
appropriate for the highest voltage.

5.6 Protection against electric shock
5.6.1

Electrical enclosures

When the truck is in its normal operating condition the electrical enclosures shall provide degree of protection
IPxxB for all live parts. However for top surfaces which are readily accessible the minimum degree of
protection shall be IPxxD (see EN 60529:1991). For voltages in excess of 120 V d.c. or 50 V a.c. it shall not
be possible to open these enclosures without a key or a tool.
5.6.2

Indirect contact

Protection against indirect contact shall be achieved by electric separation in accordance with 6.3.3 of
EN 60204-1:1992.
5.6.3

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)

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

d)

the screen of screened cables and components. This condition shall meet the requirements of 5.7.1.

5.6.4

Control and auxiliary circuits

Control and auxiliary circuits shall have a voltage not exceeding 120 V d.c. or 50 V a.c. Where the generator
output is in excess of these levels the control and auxiliary circuit shall be electrically and galvanically
separated from the power source.
5.6.5

Equipotential bonding

For voltages in excess of 120 V d.c. and 50 V a.c. equipotential bonding shall be provided between the frame
of the vehicle and metallic electrical enclosures, e.g. motor frames.

13


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EN 1175-3:1998+A1:2010 (E)

5.7 Dielectric test (type test)
5.7.1

Performance

Trucks shall be designed to be capable of complying with a type test applied to a new dry vehicle. An
alternating test voltage in accordance with 5.7.3, with a frequency between 25 Hz and 100 Hz, shall be used
for testing between live parts and the frame. It shall be supplied from a transformer with a minimum rating of
500 V.A.
5.7.2

Electronic components

Semiconductors or similar electronic components liable to become damaged by application of the test voltage
may be bypassed or disconnected. Items a) and b) of 5.6.3 shall be disconnected.
5.7.3

Test voltage

The equipment shall be capable of withstanding an alternating test voltage for 1 min as shown in table 1.
Table 2 — Test voltage
Nominal voltage U

Alternating effective test voltage

U ≤ 96 V

1 000 V

U > 96 V

2 U + 1000, in volt, with a minimum of 1500

If a second test should be needed, the alternating test voltage shall be reduced to 80 % of the test voltage
specified in the table above.

5.8
5.8.1

Insulation resistance test (routine test)
Test voltage

The test voltage shall be greater than the nominal voltage and ≤ 1000 V.
5.8.2

Insulation resistance of truck

The insulation resistance between live parts and frame of all electrical components of the truck shall be
deemed adequate if it amounts to at least 1000 Ω multiplied by the nominal voltage of the truck system.

5.9
5.9.1

!Electromagnetic radiations
Non ionising radiations

Where trucks are fitted with functional related non-ionising radiation devices (e.g. radio transmitter, RFID
reader, data collection system), the radiation shall be minimized with consideration to the influence to persons,
in particular with active or non-active implantable medical devices.
5.9.2

Electromagnetic compatibility

Any functional electromagnetic emission and the immunity of the electric/electronic systems shall be within the
limits of EN 12895:2000."

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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

6

Information for use

NOTE
The main information for use is detailed in the truck standards as listed in the foreword section. The following
are additional requirements.

6.1 Electrical diagram
A circuit diagram complying with clause 19 of EN 60204-1:1992 shall be included in the service manual.

6.2 Safety checks

Methods and intervals for checking safety systems shall be included in the service manual or instruction
handbook.

6.3 Minimum marking
Electrical enclosures for trucks with nominal voltages in excess of 120 V d.c or 50 V a.c. shall bear a durable
warning sign complying with 18.2 of EN 60204-1:1992.

6.4 !Non-ionising radiation
If the truck, after the commissioning, can be equipped with devices (e.g. radio transmitter, RFID reader, data
collection system) that are likely to emit non-ionising radiation which can cause harm to persons, in particular
persons with active or non-active implantable medical devices, a warning shall be given in the instruction
manual. If those auxiliary devices are installed by the user, the user itself shall ensure that the supplier
instructions are fulfilled and/or no harm for the persons has risen.
Where trucks are fitted with non-ionising radiation devices warning signs shall be installed."

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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

Annex A
(normative)
Generators - Output and test rules

This Annex specifies together with Annex B of EN 1175-1:1998, the manufacturing and test rules and the
criteria of output for direct current generators with rated voltages up to and including 240 V for internal
combustion powered trucks.

It covers also the classification and electric performance of d.c. generators having rated voltages up to 240 V,
forming part of the electrical equipment of internal combustion powered trucks and tractors.
It contains only additions to or deviations from the requirements in Annex B of EN 1175-1:1998.
NOTE
In Annex B of EN 1175-1:1998 frequently the term electric motor or motor is used. Here it can equate with
electric machine or machine and means motor or generator.

A.1 Normative references
For the purposes of this annex, the following normative reference applies:
EN 1175-1:1998

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

A.2 Definitions
For the purposes of this annex the following definitions apply:
A.2.1
rated rotational frequency of generator
the frequency assigned by the manufacturer. This frequency is equivalent to the rated frequency of the
internal combustion engine, if the generator is directly coupled with the engine
A.2.2
rated voltage of generator
for the generator two rated voltages is assigned by the manufacturer in accordance with the continuous rated
output defined in A.2.3.1
A.2.3
rated generator output
the output in kW at the terminals of the generator assigned by the manufacturer
A.2.4
continuous rated output of generator
for the generator two continuous outputs are assigned. The first is determined by the temperature rise of the

windings carrying the load current (higher value of the load-current and lower voltage); the second is
determined by the temperature rise of the field windings at maximum excitation (lower value of the loadcurrent with higher voltage). Both continuous rated outputs correspond to points of the full-load characteristic
defined in A.3.1

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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

A.3 Requirements
A.3.1 Characteristic curves
The current of the generator driven by an internal combustion engine is so regulated, that the available power
is absorbed. The product of current and voltage is within the limit of the regulation constant. The characteristic
curve for the maximum available input is defined as the full-load characteristic. Plotted shall be voltage and
efficiency as functions of the load-current. Each curve shall indicate the excitation, the input power and the
generator speed. The efficiency shall be specified at least for the two continuous rated outputs. The excitation
power shall be in the efficiency.

A.3.2 Tolerances on characteristic curves
At the two specific rated continuous outputs the rated current and the rated voltage shall not deviate more
than ± 5% from the corresponding values of the type-characteristic and the losses calculated from the
measured efficiency shall not exceed by more than 15 % the specific values.

A.4 Testing
A.4.1 Type tests
A.4.1.1

Continuous rated output

The generator shall be tested at the two continuous rated outputs defined in A.2.4 and the result shall comply
with the requirements of B.4.3 of EN 1175-1:1998.
A.4.1.2

Characteristic curves and efficiency

These tests shall be carried out with the generator windings as near to the appropriate temperature limit as is
practicable. Readings shall be taken at a sufficient number of current values to enable the characteristic
curves to be verified over the whole range of operation of the generator. The results shall comply with the
requirements in A.3.2.
NOTE
These tests can be carried out with cold windings by special agreement between manufacturer and user if
required for routine test comparison.

A.4.1.3

Overspeed and dielectric tests

These tests shall be carried out in accordance with B.4.6 and B.4.7 of EN 1175-1:1998 respectively.

A.4.2 Routine tests
These tests shall be agreed between manufacturer and user but are normally comprising:
A.4.2.1

Soundness

Generators shall be run for sufficient time to demonstrate electrical and mechanical soundness.
A.4.2.2

Characteristic

The rated voltage and the rated current for the two rated continuous outputs shall be checked and be within
the limits given in A.3.2. No efficiency measurements are required for routine tests.

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BS EN 1175-3:1998+A1:2010
EN 1175-3:1998+A1:2010 (E)

A.4.2.3

Commutation

Commutation should be observed when the generator is on the test bed to confirm satisfactory operation.
A.4.2.4

Overspeed and insulation tests

To be carried out in accordance with B.4.6 and B.4.7 of Annex B of EN 1175-1:1998.

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