ISO 13063:2012

INTERNATIONAL ISO
STANDARD 13063
First edition
2012-09-15
Electrically propelled mopeds and
motorcycles — Safety specifications
Cyclomoteurs et motocycles à propulsion électrique —
Spécifications de sécurité
Reference number
ISO 13063:2012(E)
©
ISO 2012

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ISO 13063:2012(E)
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© ISO 2012
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Published in Switzerland
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ISO 13063:2012(E)
Contents Page
Foreword .v
1 Scope . 1
2 Normative references . 1
3  Terms and definitions . 1
4 Environmental and operational conditions . 5
5 Voltage classes . 5
6 Marking . 5
6.1 Marking of voltage class B electric components . 5
6.2 Marking of voltage class B wiring . 5
7 Requirements and measures of voltage class A electric components .6
7.1 Requirements of voltage class A electric components . 6
7.2 Test procedures for the protection measures of voltage class A electric components . 7
8 Measures and requirements for protection of persons against electric shock of voltage
class B electric components . 8
8.1 General requirements of voltage class B electric components and RESS . . 8
8.2 Basic protection measures of voltage class B electric components and RESS . 8
8.3 Protection under first failure conditions of voltage class B electric components and RESS 8
8.4 Alternative approach for protection against electric shock of voltage class B electric
components and RESS . 9
8.5 Creepage distance of voltage class B electric components and RESS . 9
8.6 Clearance of voltage class B electric components and RESS .10
8.7 Requirements of barrier/enclosures of voltage class B electric components.11
8.8 Requirements for insulation of voltage class B electric components and RESS .11
8.9 Insulation requirements of the voltage class B RESS .11
8.10 Isolation resistance requirements of the electric system and electric circuit .12
8.11 Requirements for withstand voltage of voltage class B electric components and RESS .12
8.12 Requirements of potential equalization of voltage class B electric components
and RESS .12
8.13 Requirements for vehicle charging inlet of voltage class B electric components
and RESS .13
8.14 RESS of voltage class B over-current interruption .13
9 Test procedures for the protection measures against electric shock for voltage class B
electric components and RESS .13
9.1 General .13
9.2 Isolation resistance measurements for voltage class B electric circuits .13
9.3 Isolation resistance measurement for the voltage class B electric power sources .15
9.4 Withstand voltage test for the voltage class B electric components .16
9.5 Continuity test for potential equalization.18
10 Requirements for safety means and protection of persons against hazardous situations .18
10.1 Requirements for the emission of hazardous gases and other hazardous substances .18
10.2 Requirements for safety means and protection of persons against hazardous situations
from RESS .18
11 Operational safety .19
11.1 Propulsion system, power-on/power-off procedure .19
11.2 Connection of the vehicle to an off-board electric power supply .19
11.3 Driving partially .19
11.4 Driving backwards .20
12 Protection against failure .20
12.1 Fail safe design .20
12.2 First failure response . .20
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ISO 13063:2012(E)
12.3 Unintentional vehicle behaviour .20
13 Electromagnetic compatibility .20
13.1 Susceptibility .20
13.2 Emissions .21
14 Emergency Response .21
15 Owner’s guide manual .21
Bibliography .22
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ISO 13063:2012(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International
Standards adopted by the technical committees are circulated to the member bodies for voting.
Publication as an International Standard requires approval by at least 75 % of the member bodies
casting a vote.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights.
ISO 13063 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 23, Mopeds.
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INTERNATIONAL STANDARD ISO 13063:2012(E)
Electrically propelled mopeds and motorcycles — Safety
specifications
IMPORTANT — The colours represented in the electronic file of this document can be neither
viewed on screen nor printed as true representations. Although the copies of this document
printed by ISO have been produced to correspond (with an acceptable tolerance as judged by the
naked eye) to the requirements of ISO 3864-4, it is not intended that these printed copies be used
for colour matching. Instead, consult ISO 3864-4, which provides colorimetric and photometric
properties together with, as a guideline, references from colour order systems.
1 Scope
This International Standard specifies requirements for functional safety means, protection against
electric shock and the on-board rechargeable energy storage systems intended for the propulsion of any
kind of electrically propelled mopeds and motorcycles when used in normal conditions.
It is applicable only if maximum working voltage of the on-board electrical circuit does not exceed
1000 V a.c. or 1500 V d.c.
This International Standard does not provide comprehensive safety information for manufacturing,
maintenance and repair personnel.
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 referenced
document (including any amendments) applies.
ISO 3864-1, Graphical symbols — Safety colours and safety signs — Part 1: Design principles for safety signs
and safety markings
ISO 6469-3, Electrically propelled road vehicles — Safety specifications — Part 3: Protection of persons
against electric shock
ISO 20653, Road vehicles — Degrees of protection (IP-code) — Protection of electrical equipment against
foreign objects, water and access
IEC 60227-1, Polyvinyl chloride insulated cables of rated voltages up to and including 450/750 V — Part 1:
General requirements
IEC 60245-1, Rubber insulated cables — Rated voltages up to and including 450/750 V — Part 1: General
requirements
IEC 60479-1:2005, Effects of current on human beings and livestock — Part 1: General aspects
IEC 60664-1, Insulation coordination for equipment within low-voltage systems — Part 1: Principles,
requirements and tests
IEC 60950-1, Information technology equipment — Safety — Part 1: General requirements
3  Terms and definitions
For the purposes of this document, the following terms and definitions apply.
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ISO 13063:2012(E)
3.1
auxiliary electric system
on-board vehicle system, other than for vehicle propulsion, which operates on electric energy
3.2
balance of electric power system
remaining portion of an electric power system when the power sources (e.g. fuel cell stacks, batteries)
are disconnected
3.3
barrier
part providing protection against direct contact from any usual direction of access
3.4
basic insulation
insulation applied to live parts for protection against direct contact under fault-free conditions
NOTE Basic insulation does not necessarily include isolations used exclusively for functional purposes.
3.5
basic protection
protection against direct contact with live parts under fault-free conditions
3.6
battery-electric vehicle
BEV
electric vehicle with only a traction battery as the power source for vehicle propulsion
NOTE The abbreviation BEV is often shortened to EV.
3.7
battery pack
single mechanical assembly comprising battery cells and retaining frames or trays and possibly
components for battery management
3.8
BEV operating mode
in operating mode of an HEV, in which only the RESS is used for energy supply for vehicle propulsion and
possibly auxiliary electric systems
3.9
conductive part
conductor
part capable of conducting electric current
3.10
creepage distance
shortest distance along a surface of a solid insulating material between two conductive parts
3.11
direct contact
contact of persons with live parts
3.12
double insulation
insulation system comprising both basic insulation and supplementary insulation
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ISO 13063:2012(E)
3.13
drive direction control
device physically actuated by the rider for selecting the driving direction of the road vehicle (forward
or backward)
EXAMPLE Lever or push-button switch.
3.14
driving-enabled mode
only operating mode in which the vehicle can be moved by its own propulsion system
3.15
electric chassis
conductive parts of a vehicle that are electrically connected and whose potential is taken as reference
3.16
electric drive
combination of an electric motor and associated power electronics for the conversion of electric to
mechanical power and vice versa
3.17
electric power system
electric circuit, containing electric power sources (e.g. fuel cell stacks, batteries)
3.18
electric shock
physiological effect resulting from an electric current passing through a human body
3.19
electrically propelled vehicle
EPV
vehicle with one or more electric drive(s) for vehicle propulsion
3.20
enclosure
part providing protection of equipment against direct contact from any direction
3.21
exposed conductive part
conductive part of the electric equipment that can be touched by a test finger according to IPXXB after
removing barriers/enclosures that can be removed without using tools and that is not normally live, but
which may become live under fault conditions
NOTE Protection degrees (e.g. IPXXB) are defined in ISO 20653.
3.22
hybrid electric vehicle
HEV
vehicle with at least one RESS and one fuelled power source for vehicle propulsion
EXAMPLE ICE or fuel-cell systems are typically types of fuelled power sources.
3.23
isolation-resistance monitoring system
system which periodically or continuously monitors the isolation resistance between live parts and the
electric chassis or exposed conductive parts
3.24
isolation resistance
resistance between live parts of voltage class B electric circuit and the electric chassis or exposed
conductive parts as well as the voltage class A system
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ISO 13063:2012(E)
3.25
live part
conductor or conductive part intended to be electrically energized in normal use
3.26
maximum working voltage
highest value of a.c. voltage (rms) or of d.c. voltage which may occur in an electric system under any
normal operating conditions according to manufacturers’ specifications, disregarding transients
3.27
potential equalization
electric connections of exposed conductive parts of the electric equipment to minimize differences in
potential between these parts
3.28
protection degree
protection provided by a barrier/enclosure related to the contact with live parts by a test probe, such as
a test finger (IPXXB), a test rod (IPXXC), or a test wire (IPXXD)
NOTE Protection degrees (e.g. IPXXB, IPXXC or IPXXD) are defined in ISO 20653.
3.29
rechargeable energy storage system
RESS
system that stores energy for delivery of electric energy and which is rechargeable
EXAMPLE Batteries, capacitors.
3.30
reinforced insulation
insulation of live parts for protection against electric shock equivalent to double insulation
NOTE Reinforced insulation does not imply that the insulation shall be a homogeneous piece. The reinforced
insulation may comprise several layers which cannot be tested individually as supplementary or basic insulation.
3.31
supplementary insulation
independent insulation applied in addition to basic insulation for protection against electric shock in the
event of a failure of the basic insulation
3.32
traction battery
propulsion battery
battery
collection of all battery packs, which are electrically connected, for the supply of electric power to the
electric drive and conductively connected auxiliary system, if any
3.33
voltage class A
classification of an electric component or circuit as belonging to voltage class A, if its maximum working
voltage is ≤ 30 V a.c. or ≤ 60 V d.c., respectively
3.34
voltage class B
classification of an electric component or circuit as belonging to voltage class B, if its maximum working
voltage is (> 30 and ≤ 1000) V a.c. or (> 60 and ≤ 1500) V d.c., respectively
3.35
wiring
a system of wires providing electric circuits and including cables and connectors
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ISO 13063:2012(E)
4 Environmental and operational conditions
The requirements given in this International Standard shall be met across the range of environmental
and operational conditions for which the electrically propelled vehicle is designed to operate, as specified
by the vehicle manufacturer.
NOTE See ISO 16750 for guidance.
5 Voltage classes
Depending on its maximum working voltage U, an electric component or circuit belongs to one of the
voltage classes specified in Table 1.
Table 1 — Voltage classes
Dimensions in volts
Maximum working voltage
Voltage class
d.c. a.c.
A 0 < U ≤ 60 0 < U ≤ 30
B 60 < U ≤ 1500 30 < U ≤ 1000
NOTE The values 60 V d.c. and 30 V a.c. are selected taking into account humid weather
conditions.
6 Marking
6.1 Marking of voltage class B electric components
The symbol shown in Figure 1 shall appear on (preferably) or near voltage class B electric energy storage
systems as RESS and fuel cell stacks. The same symbol shall be visible on barriers and enclosures,
which, when removed expose live parts of voltage class B circuits. Accessibility and removability of
barriers/enclosures should be considered for the necessity of the symbol. The symbol background shall
be yellow, the bordering and the arrow shall be black in accordance with ISO 3864-1.
Figure 1 — Symbol of voltage class B electric components
6.2 Marking of voltage class B wiring
The outer covering of cables and harness for voltage class B circuits, not within enclosures or behind
barriers shall be marked with orange colour.
NOTE 1 Voltage class B connectors can be identified by the harnesses to which the connector is attached.
NOTE 2 Specifications of orange colour are given, e.g., in standards in the US (8.75R5.75/12.5) and in Japan
(8.8R5.8/12.5), according to the Munsell colour system.
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ISO 13063:2012(E)
7 Requirements and measures of voltage class A electric components
7.1 Requirements of voltage class A electric components
7.1.1 General requirements of voltage class A electric components
The electrical control system shall be designed so that, should it malfunction in a hazardous manner, it
shall switch off power to the electric motor.
Safety and compatibility of the combination between RESS and any auxiliary electric energy supplies
shall be ensured, according to the manufacturer’s specifications.
7.1.2 General requirements of barrier/enclosures of voltage class A electric components
If protection may be provided by barriers/enclosures, live parts may be placed inside enclosures or
behind barriers, preventing access to the live parts from any usual direction of access.
The barriers/enclosures provide sufficient mechanical resistance under normal operating conditions,
as specified by the manufacturer.
7.1.3 Requirements of voltage class A electric cables and connections
Cable and plug temperature shall be lower than that specified by the manufacturer of the cables and
plugs. There shall be no corrosion on plug pins and no damage to cable and plug insulation.
Compliance shall be checked by the test described in 7.2.1.
7.1.4 Requirements of voltage class A wiring
The following provisions apply to voltage class A wiring:
a) Wire ways shall be smooth and free from sharp edges.
b) Wires shall be protected so that they do not come into contact with burrs, cooling fins or similar
sharp edges that may cause damage to their insulation. Holes in metal through which insulated
wires pass shall have smooth well-rounded surfaces or be provided with bushings.
c) Wiring shall be effectively prevented from coming into contact with moving parts.
Separate parts of the RESS that can move in normal use or during user maintenance relative to each
other, shall not cause undue stress to electrical connections and internal conductors, including those
providing earthing continuity.
Compliance with a), b), c) shall be checked by inspection.
d) If an open coil spring is used, it shall be correctly installed and insulated. Flexible metallic tubes
shall not cause damage to the insulation of the conductors contained within them.
Compliance with d) shall be checked by inspection. If flexing occurs in normal use, the appliance is
placed in its normal operational position and is supplied at rated voltage under normal operation.
e) The movable part is moved backwards and forwards, so that the conductor is flexed through the
largest angle permitted by its construction.
Compliance with e) shall be checked by the test described in 7.2.2.
f) The insulation of internal wiring shall withstand the electrical stress likely to occur in normal use.
Compliance with f) shall be checked by the test described in 7.2.2. The wiring shall not reduce the basic
insulation adopted by the manufacturer or the basic insulation shall be electrically equivalent to the
basic insulation of cords complying with IEC 60227-1 or IEC 60245-1.
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ISO 13063:2012(E)
7.1.5 Requirements of voltage class A power cables and conduits
Conduit entries, cable entries and knockouts shall be constructed or located so that the introduction of
the conduit or cable does not reduce the protection measures adopted by the manufacturer. Compliance
is checked by inspection.
7.2 Test procedures for the protection measures of voltage class A electric components
7.2.1 Test method of voltage class A electric cables and connections
Cable and plug temperature shall be checked by the following test method.
Discharge the fully charged RESS to the discharging limit at the maximum allowable current specified
by the vehicle manufacturer and record the current.
Measure the cable and plug temperatures and ensure that they are lower than the levels specified by the
manufacturer.
7.2.2 Test method of voltage class A wiring
7.2.2.1 Test method for the movable part of the voltage class A wiring
The flexibility of movable part of the wires shall be checked by the following test method.
The wires shall maintain to flex the largest angle specified by manufacturer or permitted by the
construction after the test.
The wires shall be flexed with the largest angle specified by the manufacturer or permitted by the
construction for 10.000 cycles with the test frequency of 0,5 Hz at (20 ± 5) °C.
After the above flexibility test, the wire shall be tested for the electrical strength as described in 7.2.2.2.
7.2.2.2 Test method for the voltage withstanding electrical strength
The wiring and the connectors shall be checked by the electrical strength test.
The test voltage, expressed in volts, shall be equal to (500 + 2 x V ) for 2 min and applied between live
r
parts and other metal parts only.
NOTE V is the rated voltage.
r
Or, the safety and compatibility of the wires for the voltage withstanding electrical strength, shall be
ensured by the vehicle manufacturer.
To perform the test of the voltage withstanding electrical strength, the vehicle need to be prepared as follows:
a) traction batteries shall be disconnected at their terminals from the power system;
b) electric power sources of the voltage class A power systems other than the traction batteries (fuel
cell stacks, capacitors) may be disconnected at their terminals from the power system; if they
remain connected power generation shall be deactivated;
c) all live parts of the balance of the voltage class A power systems shall be connected to each other;
d) all exposed conductive parts of the voltage class A power systems shall be connected to the
electric chassis.
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ISO 13063:2012(E)
8 Measures and requirements for protection of persons against electric shock of
voltage class B electric components
8.1 General requirements of voltage class B electric components and RESS
Protection against electric shock shall be comprised of
a) basic protection measures against direct contact with live parts (basic protection), and
b) measures for protection under first failure conditions.
The protection measures shall meet the requirements as described in 8.2 and 8.3 and compliance shall
be tested according to test methods specified in Clause 9.
8.2 Basic protection measures of voltage class B electric components and RESS
Persons shall be protected against direct contact with the live parts of the voltage class B electrical circuits.
The protections measures against direct contact shall be provided by either one or both of the following:
a) basic insulation of the live parts;
b) barriers/enclosures, preventing access to the live parts.
The barriers/enclosures may be electrically conductive or non-conductive.
8.3  Protection under first failure conditions of voltage class B electric components and
RESS
8.3.1 General
The voltage class B circuits shall have sufficient isolation resistance according to requirements in 8.7.
If the minimum isolation resistance requirement (see 8.7) cannot be maintained under all operational
conditions and over the entire service life, one of the following measures shall be applied:
a) monitoring of the isolation resistance periodically or continuously. An appropriate warning shall be
provided if loss of isolation resistance is detected. The voltage class B system may be deactivated
depending on the operational state of the vehicle or the ability to activate the voltage class B system
may be limited;
b) double insulation or reinforced insulation;
c) an
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