oSIST prEN 17860-5:2023

SLOVENSKI STANDARD
oSIST prEN 17860-5:2023
01-oktober-2023
Tovorna kolesa - 5. del: Električni vidik
Carrier cycles - Part 5: Electrical aspects
Lastenfahrräder - Teil 5: Elektrische Aspekte
Cycles utilitaires - Partie 5: Aspects électriques
Ta slovenski standard je istoveten z: prEN 17860-5
ICS:
43.150 Kolesa Cycles
oSIST prEN 17860-5:2023 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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oSIST prEN 17860-5:2023

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oSIST prEN 17860-5:2023


DRAFT
EUROPEAN STANDARD
prEN 17860-5
NORME EUROPÉENNE

EUROPÄISCHE NORM

August 2023
ICS 43.150
English Version

Carrier cycles - Part 5: Electrical aspects
 Lastenfahrräder - Teil 5: Elektrische Aspekte
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee
CEN/TC 333.

If this draft becomes a European Standard, 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.

This draft European Standard was established by CEN 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-CENELEC
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, Republic of North Macedonia, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and
United Kingdom.

Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are
aware and to provide supporting documentation.

Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without
notice and shall not be referred to as a European Standard.


EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2023 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 17860-5:2023 E
worldwide for CEN national Members.

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Contents Page
European foreword . 4
Introduction . 5
1 Scope . 6
2 Normative references . 6
3 Terms and definitions . 7
4 General requirements . 8
4.1 Risk assessment . 8
4.2 Significant hazards and safety functions . 8
4.2.1 Significant hazards . 8
4.2.2 Safety function for control system of carrier EPACs . 8
4.3 Prevention of unauthorized use . 9
5 Electrical requirements . 9
5.1 Electric system . 9
5.2 Controls and symbols . 9
5.3 Battery . 9
5.4 External battery charger . 10
5.5 Electric cables and couplers . 10
5.5.1 General. 10
5.5.2 Requirements . 10
5.5.3 Test method . 10
5.6 Wiring . 10
5.7 Power cables and conduits . 11
5.8 External and internal electrical connections . 11
5.9 Moisture resistance . 11
5.10 Mechanical strength test of the electrical components . 11
5.10.1 General. 11
5.10.2 Function related shock test . 11
5.10.3 Impact related shock test - Lateral overturning . 12
5.11 Maximum speed for which the electric motor gives assistance . 12
5.11.1 Requirements . 12
5.11.2 Test method . 12
5.12 Walk and manoeuvring assistance mode . 13
5.12.1 Requirements . 13
5.12.2 Test method . 13
5.13 Power management . 14
5.13.1 Requirements . 14
5.13.2 Test method – Auxiliary electric motor management . 14
5.14 Measurement of the maximum continuous rated power . 15
5.14.1 Requirements . 15
5.14.2 Measurement . 16
5.14.3 Alternative measurement . 16
5.15 Electro magnetic compatibility . 18
5.15.1 Emission . 18
5.15.2 Immunity. 18
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5.15.3 Carrier EPAC in mains charging mode . 18
5.16 Failure mode . 19
5.16.1 Acoustical and / or visual warning . 19
5.16.2 Moving the vehicle . 19
5.17 Anti-tampering measures . 20
5.18 Thermal hazards . 20
5.18.1 Non-continuous contact surface . 20
5.18.2 Continuous contact surface . 20
5.18.3 Ambient temperature . 20
5.19 Recuperative braking . 21
5.20 Electrical requirements for electric cargo trailers . 21
5.20.1 Control for electric cargo trailers . 21
5.20.2 Handcart mode for electric cargo trailers - Handcart mode speed test. 21
5.20.3 Maximum speed test . 21
5.20.4 Assistance power for electric cargo trailer . 21
5.20.5 Additional anti-tempering measures for electric cargo trailers . 26
5.20.6 Plug connections for electric cargo trailers . 26
5.20.7 Performance levels (PLrs) for control system of electric cargo trailers . 27
Annex A (normative) Electromagnetic compatibility of carrier EPAC and ESA . 28
Annex B (normative) Light, warning device, on/off symbols . 29
Annex C (informative) Walk and manoeuvring assistance mode symbols . 30
Bibliography . 31


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European foreword
This document (prEN 17860-5:2023) has been prepared by Technical Committee CEN/TC 333 “Cycles”,
the secretariat of which is held by UNI.
This document is currently submitted to the CEN Enquiry.
This document is part of standard series consisting of the following parts:
— prEN 17860-1:2022, Carrier cycles — Part 1: Terms and definitions
— prEN 17860-2:2022, Carrier cycles — Part 2: Lightweight single track carrier cycles — Mechanical
aspects
— prEN 17860-3:2022, Carrier Cycles - Part 3: Lightweight multi track carrier cycles — Mechanical
aspects
— prEN 17860-4, Carrier Cycles — Part 4: Heavy weight carrier cycles — Mechanical and functional
aspects
— prEN 17860-5:2023, Carrier cycles — Part 5: Electrical aspects
— prEN 17860-6, Carrier Cycles — Passenger transport
— prEN 17860-7:2023, Carrier cycles — Cargo trailers

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Introduction
This document has been developed in response to an increased demand throughout Europe for carrier
cycles of a type which are excluded from the scope of Regulation (EU) No 168/2013. Electrical aspects of
electric trailers and other peripherals such as chargers are also part of this document.

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1 Scope
This document applies to:
— functional and electrical safety aspects of carrier cycles covered in all parts of EN 17860;
— electrical aspects of electrically power assisted cycle trailers (EPACT) covered in prEN 17860-7;
— electrical aspects of batteries used for carrier cycles;
— electrical aspects of chargers used for carrier cycles.
This document does not apply to charging stations.
This document specifies requirements and test methods for motor power management systems,
electrical circuits including the charger for the assessment of the design and assembly of carrier cycles
and subassemblies for systems having a Safety Extra Low Voltage (SELV) maximum working
voltage ≤ 60 V d.c. disregarding transients.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content
constitutes requirements 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.
prEN 17860-2:2022, Carrier cycles — Part 2: Lightweight single track carrier cycles — Mechanical aspects
EN 15194:2017, Cycles — Electrically power assisted cycles — EPAC Bicycles
EN ISO 7010, Graphical symbols — Safety colours and safety signs — Registered safety signs (ISO 7010)
EN ISO 12100, Safety of machinery — General principles for design — Risk assessment and risk reduction
(ISO 12100:2010)
EN ISO 13849 (all parts), Safety of machinery — Safety-related parts of control systems
CEN/TS 17831:2023, Cycles — Electrically power assisted cycles — Anti-tampering measures
EN 50604-1:2016, Secondary lithium batteries for light EV (electric vehicle) applications — Part 1: General
safety requirements and test methods
EN 50604-1:2016/A1:2021, Secondary lithium batteries for light EV (electric vehicle) applications —
Part 1: General safety requirements and test methods
IEC 60034-1, Rotating electrical machines — Part 1: Rating and performance
EN 60068-2-27, Environmental testing — Part 2-27: Tests — Test Ea and guidance: Shock (IEC 60068-2-
27)
IEC 60335-1, Household and similar electrical appliances — Safety — Part 1: General requirements
EN 60335-2-29, Household and similar electrical appliances — Safety — Part 2-29: Particular
requirements for battery chargers (IEC 60335-2-29)
HD 60364-5-52:2011, Low-voltage electrical installations — Part 5-52: Selection and erection of electrical
equipment — Wiring systems
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EN 60417, Graphical symbols for use on equipment
EN 60529, Degrees of protection provided by enclosures (IP Code) (IEC 60529)
EN IEC 61000-6-1, Electromagnetic compatibility (EMC) — Part 6-1: Generic standards — Immunity
standard for residential, commercial and light-industrial environments
EN IEC 61000-6-3, Electromagnetic compatibility (EMC) — Part 6-3: Generic standards — Emission
standard for equipment in residential environments
ISO 13732-1, Ergonomics of the thermal environment — Methods for the assessment of human responses to
contact with surfaces — Part 1: Hot surfaces
3 Terms and definitions
For the purposes of this document, the terms and definitions given in prEN 17860-1:2022 and the
following apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https://www.iso.org/obp/
— IEC Electropedia: available at https://www.electropedia.org/
3.1
corrected crank power
crank power corrected by the factor for the efficiency of the pedal and drive system (at the ideal point,
with specification of speed at the drive wheel, crank speed and crank torque according to the data sheet)
3.2
continuous rated power
output power of the motor specified be manufacturer by design, measured when the motor reaches its
thermal equilibrium at given ambient conditions
3.3
cut off speed
speed reached, by the carrier EPAC, at the moment the current has dropped to zero or to the no load
current value
3.4
electrically assisted cycle trailers
EPACTs
cargo trailer, equipped with auxiliary electric motor, whereas the electric motor only propels by the
movement of the towing cycle, except in the hand-cart assistance mode
3.5
no load current point
current for which there is no torque on the driving wheel
3.6
recuperative braking
regenerative braking
braking recovering part of the kinetic energy that would otherwise turn into heat and instead converting
it into electricity
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3.7
road power
sum of the mechanical power transmitted to the road
3.8
serial hybrid carrier EPAC
series hybrid carrier EPAC
carrier EPAC with a pedal driven generator which is connected electrically to an electric machine to drive
the wheels
3.9
thermal equilibrium
temperatures of motor parts which do not vary more than 2 K per hour
4 General requirements
4.1 Risk assessment
Carrier EPACs and electrically assisted cycle trailers (EPACTs) shall be designed in accordance with the
principles of EN ISO 12100 for relevant hazards which are not dealt with by this document. This includes
evaluation of such risks for all relevant components.
4.2 Significant hazards and safety functions
4.2.1 Significant hazards
The following significant hazards of carrier EPACs have been considered in this document:
a) mechanical hazards: deceleration, acceleration, instability, kinetic energy, rotating elements and
moving elements, rough or slippery surfaces, sharp edges;
b) electrical hazards: electromagnetic phenomena, electrostatic phenomena, overload, short-circuit,
thermal radiation;
c) thermal hazards: explosion, flame, radiation from heat sources, objects or materials with a high or
low temperature;
d) ergonomic hazards: effort, local lighting, posture;
e) hazards associated with the environment in which the carrier EPAC is used: water (dust).
4.2.2 Safety function for control system of carrier EPACs
4.2.2.1 General
The carrier EPAC control system risk shall be assessed in accordance with the series of EN ISO 13849.
4.2.2.2 Requirements for the safety related parts of the electrical control systems
The safety requirements of Table 1 shall be necessary for a carrier EPAC. If necessary, the manufacturer
shall add more safety requirements and determine the necessary PL or safety level for each of these safety
requirements and the related safety functions.
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Table 1 — Safety functions related to defined hazards
Safety function Performance Level
Prevention of electric motor assisted
propulsion without user request by pedalling or PLr c
by activation of the walk assistance mode
Prevention of risk of fire in case of management
system failure for batteries with electric energy PLr c
above 100 Wh

4.2.2.3 Verification of the safety functions
The whole procedure for achieving functional safety shall be in accordance with the series of
EN ISO 13849.
System suppliers shall document this process and take measures to achieve the required performance
level (see Table 1).
The minimum set of safety related functions shall be implemented at least by both, system suppliers and
the manufacturer, to achieve conformity with this document.
4.3 Prevention of unauthorized use
Means shall be provided to the user to prevent an unauthorized use of the electric assistance/walk
assistance mode of the carrier EPAC e.g. key, locks, electronic control device.
5 Electrical requirements
5.1 Electric system
The electrical system shall be designed so that, should it malfunction in a hazardous manner, it shall
switch off power to the malfunctioning parts without increasing the hazard. It shall require user
interaction to switch on again.
NOTE The mechanical brakes provide fast and safe stopping in emergency situations.
5.2 Controls and symbols
A control device shall be fitted to switch on and off the assistance.
Two independent applying actions shall be required to start the electrical assistance mode (e.g. power
switch and forward pedalling activation); a traffic caused stop (e.g. traffic lights) is not subject to this
requirement.
The control device shall be apparent, easy to reach and unmistakable. This control device shall be
activated by voluntary action.
Designs of the on/off symbol, lighting symbol and audible warning device symbol shall be in accordance
with Annex B.
5.3 Battery
The battery shall comply with EN 50604-1:2016 and EN 50604-1:2016/A1:2021. At the moment of the
publication of this standard, EN 50604-1 is only applicable for secondary lithium batteries, and only risks
related to these batteries were taken into account.
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5.4 External battery charger
External battery chargers with output voltage below 60V DC shall comply with EN 60335-2-29.
The user shall be informed if the charger is designed for indoor or both indoor and outdoor use.
Battery chargers for indoor use only shall be marked with symbol IEC 60417-5957 (2004-12).
Chargers for outdoor use shall be labelled accordingly.
In case chargers are designed and labelled for outdoor use, they shall be at least IP X4.
Chargers for carrier cycles are considered to be operated in a residential (household) environment.
5.5 Electric cables and couplers
5.5.1 General
All couplers for cable and wire shall be selected to prevent corrosion of electrical contact conductance.
5.5.2 Requirements
Cable and plug temperature shall be lower than that specified by the manufacturer of the cables and plugs.
Damage to cable and plug insulation shall be prevented.
The cable cross sections shall be selected in accordance to IEC 60335-1:2020, Table 11. If these
requirements are not met, a temperature rise test shall be performed, in accordance to 5.5.3.
Cables used exclusively for communication lines are excluded.
5.5.3 Test method
At an ambient room temperature (20 ± 5) °C, discharge the fully charged carrier EPAC battery to the
discharging limit specified by the carrier EPAC or ESA manufacturer at the maximum current allowable
by the system and record it. Measure the cable and plug temperatures and ensure, by examination, that
there is no deterioration of the insulation on either assembly.
The increase of outer surface temperature of parts that can be touched shall be ≤ 60 K while in use on
performance test rig.
5.6 Wiring
Requirements on wiring shall be checked according to the following sequence at an ambient room
temperature (20 ± 5) °C.
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.
Compliance with a), b), c) shall be checked by inspection.
d) Separate parts of the carrier EPAC 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 ground continuity.
If an open coil spring is used to protect wire, it shall be correctly installed and insulated. Flexible metallic
tubes shall not cause damage to the insulation of the conductors contained within them.
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Compliance with d) shall be checked by inspection and by the following test method:
— if flexing occurs in normal use, the appliance is placed in its normal operational position and is
supplied at rated voltage under normal operation;
— the movable part is moved backwards and forwards through the largest angle permitted by its
construction;
— for conductors that are flexed in normal use, flex movable part for 10 000 cycles at a test frequency
of 0,5 Hz;
— for conductors that are flexed during user maintenance, flex the movable part for 100 cycles at the
same frequency.
5.7 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 shall be checked by inspection.
Guidance for power cables size selection is given in HD 60364-5-52:2011, 5.22.1.2, 523.1, 523.3 and
Table A.
The insulation of internal wiring shall withstand the electrical stress likely in consideration of designed
maximum current, maximum temperature and environmental conditions.
5.8 External and internal electrical connections
Electrical connection shall comply with HD 60364-5-52:2011, 526.1 and 526.2.
5.9 Moisture resistance
The electrical components of a fully assembled carrier EPAC and/or trailer shall be tested and shall
comply with at least IPX4 requirements according to EN 60529.
These requirements should be checked for each rational component or unit of Carrier EPAC (e.g. the
handle assembly including the control switch, display, lamp and other electrical components, the drive
unit, the battery unit, etc.).
NOTE 1 Battery charger is not included in the electrical components of a fully assembled Carrier EPAC.
NOTE 2 If the carrier cycle is intended for specific wet conditions a higher IP degree can be necessary.
5.10 Mechanical strength test of the electrical components
5.10.1 General
The electrical components shall have adequate mechanical strength and be constructed to withstand such
rough handling that may be expected in normal use.
NOTE 1 Both complete carrier EPAC and sub assembly conditions are acceptable.
NOTE 2 For environmental test, see DIN SPEC 79009:2018-10.
5.10.2 Function related shock test
2
In accordance with EN 60068-2-27, half sine shocks shall be applied with a peak acceleration of 150 m/s
and a duration equal to the nominal impulse of 6 ms in both directions of each of the three perpendicular
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axes. Number of shocks in each direction: (100 ± 3) shocks (a total of 600 shocks). After the test, the
performance of the components shall be fully maintained and no failure shall occur.
5.10.3 Impact related shock test - Lateral overturning
The impact related shock test shall be carried out on a fully assembled single track Carrier EPAC. The
Carrier EPAC shall be left to fall 5 times both to the left and to the right from its upright position. For this
purpose, the steering shall be aligned in the straightforward position, the ends of the handlebar shall be
fitted with handlebar grips or handlebar plugs, and cranks shall be aligned horizontally prior to each fall.
The test shall be carried out on a hard surface (concrete or sett).
NOTE 5 times to the le
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