1. Scope
This standard specifies the electrical requirements for the design and manufacture of self- propelled industrial trucks including masted and variable reach rough terrain trucks (see GB/T 6104-2005, 3.1.3.1.8), and tow tractors with a rated drawbar pull up to and including 20000N.
This standard applies to trucks with battery voltages in accordance with ISO 1044. For additional requirements of trucks with mains power, see GB 5226.1-2008.
This standard does not apply to:
——Trucks used in potentially explosive atmospheres, or
——Issues related to electromagnetic compatibility.
This standard does not repeat all the technical rules which are state of the art and which are applicable to the material used to construct the industrial truck, for which reference can be made to ISO 12100-2.
2. Normative References
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the normative document (including any amendments) applies.
GB 5226.1 – 2008 Electrical Safety of Machinery - Electrical Equipment of Machines - Part 1: General Requirements (IEC 60204-1:2005, IDT)
GB/T 16856.1 – 2008 Safety of Machinery - Risk Assessment - Part 1: Principle (ISO 14121-1:2007, IDT)
ISO 1044 Industrial Trucks - Lead-acid Traction Batteries for Electric Trucks - Preferred Voltages)
ISO 12100-2 Safety of Machinery - Basic Concepts, General Principles for Design - Part 2: Technical Principles
ISO 13849-1 Safety of Machinery - Safety-related Parts of Control Systems - Part 1: General Principles for Design
EN 50272-3 Safety Requirements for Secondary Batteries and Battery Installations - Part 3: Traction Batteries
IEC 60384-14 Fixed Capacitors for Use in Electronic Equipment - Part 14: Sectional Specification: Fixed Capacitors for Electromagnetic Interference Suppression and Connection to the Supply Mains
IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
IEC 60947-5-1 Low-voltage Switchgear and Control Gear - Part 5-1: Control Circuit Devices and Switching Elements - Electromechanical Control Circuit Devices
3. Terms and Definitions
For the purposes of this document, the following terms and definitions apply.
3.1
Arcing part
Mechanical device that interrupts current during operation.
3.2
Auxiliary circuit
Electrical circuit that controls lights, fans and other accessories.
3.3
Battery compartment
Compartment on the truck that houses the battery.
3.4
Battery enclosure
Container or tray that houses the individual cells.
3.5
Control circuit
Electrical circuitry that controls truck movement.
3.6
Deactivate
Make inactive or ineffective.
3.7
Direct contact
Contact of person with live parts.
3.8
Electrical enclosure
Compartment on a truck that houses uninsulated live electrical components.
3.9
Electrical or electronic steering
System where input is not mechanically connected to output.
3.10
Exposed conductive part
Conductive part of electrical equipment, which can be touched and which is not normally live, but which may become live under fault condition.
3.11
Frame fault
Accidental connection of a live part to the truck structure.
3.12
Indirect contact
Contact of persons with exposed conductive parts which have become live under fault conditions.
3.13
Live part
Conductor or conductive part intended to be energized in normal use.
3.14
Nominal current
Current in amperes that the electrical system is able to carry continuously without exceeding the allowable temperature indicated
3.15
Nominal voltage(of the truck system)
Total number of battery cells connected in series in the truck’s system multiplied by the nominal cell voltage.
3.16
Power circuit
Electrical circuitry that supplies the motors which cause truck movement, i.e. traction, steering and lifting.
3.17
Rated operating current
Ie
Value of current which is determined by the conditions of use of the contactor.
3.18
Rated thermal current
Ith
Value of current which determines the temperature rise conditions of the main circuit in the absence of any closing or opening operation of the contacts.
3.19
Risk of fire
Any device that has a surface temperature greater than 175℃ or that emits sparks outside of its enclosure.
3.20
Routine test
Test required for all production trucks.
3.21
Type test
Test to verify compliance with this standard for each truck type.
Foreword I
1. Scope
2. Normative References
3. Terms and Definitions
4. List of Hazards
5. Requirements
5.1 Electrical Requirements for Battery Powered Trucks
5.1.1 Traction Batteries
5.1.2 Battery Leads
5.1.3 Battery Connector
5.1.4 Battery Charging
5.1.5 Emergency Switching off Requirements (Disconnection) Connections for Batteries
5.1.6 Design Construction
5.1.7 Trucks with Nominal Battery Voltage Exceeding 120 V dc
5.1.8 Wiring and Wire Construction
5.1.9 Electrical Shock Protection [direct contact and indirect contact (spacing)]
5.1.10 Lamps and Lampholders
5.1.11 Slack/broken Chains
5.1.12 Low Voltage
5.1.13 Overcurrent Protective Devices
5.1.14 Controls - General
5.1.15 Controls - Travel
5.1.16 Controls - Load Handling
5.1.17 Control - Steering
5.1.18 Contactors
5.1.19 Truck Testing
5.2 Electrical Requirements for Internal Combustion Trucks
5.2.1 Battery
5.2.2 Circuit Protection
5.2.3 Control Systems
5.2.4 Wiring and Wire Construction
5.2.5 Electrical Shock Protection [Direct Contact and Indirect Contact (Spacing)]
6. Verification of Battery Powered Trucks
6.1 Insulation Resistance Testing (Routine Test)
6.2 Type Testing
6.2.1 Abnormal Operation
6.2.2 Temperature
6.2.3 Arc Rupture
6.2.4 Dielectric Test
6.2.5 Battery Connector Testing
6.2.6 Contactor Testing
7. Information for Use
7.1 Minimum Markings for Electric Trucks
7.1.1 Wire, Cables and Terminals
7.1.2 Battery Connectors
7.1.3 Batteries
7.1.4 Maintenance, Charging and Handling
7.1.5 Battery Compartment and Electrical Enclosures
7.1.6 Electrical Diagram
7.1.7 Safety Checks
7.2 Charging Area
7.2.1 Charging in Truck
7.2.2 Charging in a Designated Area
7.3 Minimum Marking Internal Combustion Trucks
7.3.1 Wires, Cables and Terminals
7.3.2 Electrical Diagram
7.3.3 Safety Checks
Bibliography
1. Scope
This standard specifies the electrical requirements for the design and manufacture of self- propelled industrial trucks including masted and variable reach rough terrain trucks (see GB/T 6104-2005, 3.1.3.1.8), and tow tractors with a rated drawbar pull up to and including 20000N.
This standard applies to trucks with battery voltages in accordance with ISO 1044. For additional requirements of trucks with mains power, see GB 5226.1-2008.
This standard does not apply to:
——Trucks used in potentially explosive atmospheres, or
——Issues related to electromagnetic compatibility.
This standard does not repeat all the technical rules which are state of the art and which are applicable to the material used to construct the industrial truck, for which reference can be made to ISO 12100-2.
2. Normative References
The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the normative document (including any amendments) applies.
GB 5226.1 – 2008 Electrical Safety of Machinery - Electrical Equipment of Machines - Part 1: General Requirements (IEC 60204-1:2005, IDT)
GB/T 16856.1 – 2008 Safety of Machinery - Risk Assessment - Part 1: Principle (ISO 14121-1:2007, IDT)
ISO 1044 Industrial Trucks - Lead-acid Traction Batteries for Electric Trucks - Preferred Voltages)
ISO 12100-2 Safety of Machinery - Basic Concepts, General Principles for Design - Part 2: Technical Principles
ISO 13849-1 Safety of Machinery - Safety-related Parts of Control Systems - Part 1: General Principles for Design
EN 50272-3 Safety Requirements for Secondary Batteries and Battery Installations - Part 3: Traction Batteries
IEC 60384-14 Fixed Capacitors for Use in Electronic Equipment - Part 14: Sectional Specification: Fixed Capacitors for Electromagnetic Interference Suppression and Connection to the Supply Mains
IEC 60529 Degrees of Protection Provided by Enclosures (IP Code)
IEC 60947-5-1 Low-voltage Switchgear and Control Gear - Part 5-1: Control Circuit Devices and Switching Elements - Electromechanical Control Circuit Devices
3. Terms and Definitions
For the purposes of this document, the following terms and definitions apply.
3.1
Arcing part
Mechanical device that interrupts current during operation.
3.2
Auxiliary circuit
Electrical circuit that controls lights, fans and other accessories.
3.3
Battery compartment
Compartment on the truck that houses the battery.
3.4
Battery enclosure
Container or tray that houses the individual cells.
3.5
Control circuit
Electrical circuitry that controls truck movement.
3.6
Deactivate
Make inactive or ineffective.
3.7
Direct contact
Contact of person with live parts.
3.8
Electrical enclosure
Compartment on a truck that houses uninsulated live electrical components.
3.9
Electrical or electronic steering
System where input is not mechanically connected to output.
3.10
Exposed conductive part
Conductive part of electrical equipment, which can be touched and which is not normally live, but which may become live under fault condition.
3.11
Frame fault
Accidental connection of a live part to the truck structure.
3.12
Indirect contact
Contact of persons with exposed conductive parts which have become live under fault conditions.
3.13
Live part
Conductor or conductive part intended to be energized in normal use.
3.14
Nominal current
Current in amperes that the electrical system is able to carry continuously without exceeding the allowable temperature indicated
3.15
Nominal voltage(of the truck system)
Total number of battery cells connected in series in the truck’s system multiplied by the nominal cell voltage.
3.16
Power circuit
Electrical circuitry that supplies the motors which cause truck movement, i.e. traction, steering and lifting.
3.17
Rated operating current
Ie
Value of current which is determined by the conditions of use of the contactor.
3.18
Rated thermal current
Ith
Value of current which determines the temperature rise conditions of the main circuit in the absence of any closing or opening operation of the contacts.
3.19
Risk of fire
Any device that has a surface temperature greater than 175℃ or that emits sparks outside of its enclosure.
3.20
Routine test
Test required for all production trucks.
3.21
Type test
Test to verify compliance with this standard for each truck type.
Contents of GB/T 27544-2011
Foreword I
1. Scope
2. Normative References
3. Terms and Definitions
4. List of Hazards
5. Requirements
5.1 Electrical Requirements for Battery Powered Trucks
5.1.1 Traction Batteries
5.1.2 Battery Leads
5.1.3 Battery Connector
5.1.4 Battery Charging
5.1.5 Emergency Switching off Requirements (Disconnection) Connections for Batteries
5.1.6 Design Construction
5.1.7 Trucks with Nominal Battery Voltage Exceeding 120 V dc
5.1.8 Wiring and Wire Construction
5.1.9 Electrical Shock Protection [direct contact and indirect contact (spacing)]
5.1.10 Lamps and Lampholders
5.1.11 Slack/broken Chains
5.1.12 Low Voltage
5.1.13 Overcurrent Protective Devices
5.1.14 Controls - General
5.1.15 Controls - Travel
5.1.16 Controls - Load Handling
5.1.17 Control - Steering
5.1.18 Contactors
5.1.19 Truck Testing
5.2 Electrical Requirements for Internal Combustion Trucks
5.2.1 Battery
5.2.2 Circuit Protection
5.2.3 Control Systems
5.2.4 Wiring and Wire Construction
5.2.5 Electrical Shock Protection [Direct Contact and Indirect Contact (Spacing)]
6. Verification of Battery Powered Trucks
6.1 Insulation Resistance Testing (Routine Test)
6.2 Type Testing
6.2.1 Abnormal Operation
6.2.2 Temperature
6.2.3 Arc Rupture
6.2.4 Dielectric Test
6.2.5 Battery Connector Testing
6.2.6 Contactor Testing
7. Information for Use
7.1 Minimum Markings for Electric Trucks
7.1.1 Wire, Cables and Terminals
7.1.2 Battery Connectors
7.1.3 Batteries
7.1.4 Maintenance, Charging and Handling
7.1.5 Battery Compartment and Electrical Enclosures
7.1.6 Electrical Diagram
7.1.7 Safety Checks
7.2 Charging Area
7.2.1 Charging in Truck
7.2.2 Charging in a Designated Area
7.3 Minimum Marking Internal Combustion Trucks
7.3.1 Wires, Cables and Terminals
7.3.2 Electrical Diagram
7.3.3 Safety Checks
Bibliography
