SIST EN 16796-1:2017

SLOVENSKI STANDARD
SIST EN 16796-1:2017
01-marec-2017
9R]LOD]DWDOQLWUDQVSRUW(QHUJLMVNDXþLQNRYLWRVW3UHVNXVQHPHWRGHGHO
6SORãQR
Energy efficiency of industrial trucks - Test methods - Part 1 : General
Energieeffizienz von Flurförderzeugen - Testmethoden - Teil 1: Generelles
Efficacité énergétique des chariots de manutention - Méthodes d'essai - Partie 1 :
Généralités
Ta slovenski standard je istoveten z: EN 16796-1:2016
ICS:
27.015 (QHUJLMVNDXþLQNRYLWRVW Energy efficiency. Energy
2KUDQMDQMHHQHUJLMHQD conservation in general
VSORãQR
53.060 Industrijski tovornjaki Industrial trucks
SIST EN 16796-1:2017 en,fr,de
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

---------------------- Page: 1 ----------------------

SIST EN 16796-1:2017

---------------------- Page: 2 ----------------------

SIST EN 16796-1:2017


EN 16796-1
EUROPEAN STANDARD

NORME EUROPÉENNE

November 2016
EUROPÄISCHE NORM
ICS 53.060
English Version

Energy efficiency of Industrial trucks - Test methods - Part
1: General
Efficacité énergétique des chariots de manutention - Energieeffizienz von Flurförderzeugen - Testmethoden
Méthodes d'essai - Partie 1 : Généralités - Teil 1: Generelles
This European Standard was approved by CEN on 13 August 2016.

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-CENELEC 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-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, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania,
Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and
United Kingdom.





EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION

EUROPÄISCHES KOMITEE FÜR NORMUNG

CEN-CENELEC Management Centre: Avenue Marnix 17, B-1000 Brussels
© 2016 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 16796-1:2016 E
worldwide for CEN national Members.

---------------------- Page: 3 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
Contents Page
European foreword . 4
Introduction . 5
1 Scope . 6
2 Normative references . 7
3 Terms and definitions . 8
4 Test conditions . 9
4.1 General . 9
4.2 Test equipment . 9
4.2.1 Test area . 9
4.2.2 Test track . 9
4.2.3 Test load and/or towing capacity. 9
4.3 Truck conditions . 9
4.4 Environmental conditions . 10
4.5 Truck maintenance. 10
4.6 Battery condition . 10
5 Measurement procedure . 11
5.1 General . 11
5.2 Operating sequence . 11
5.3 Electrical trucks . 11
5.3.1 General . 11
5.3.2 Truck measurement . 11
5.3.3 Battery efficiency . 12
5.3.4 Charger efficiency . 12
5.4 IC-trucks . 13
5.5 Hybrid trucks . 13
5.6 Measurement accuracy . 13
5.7 Calculation . 14
6 Documentation . 14
6.1 Test report . 14
6.2 Declaration . 15
6.2.1 Industrial truck energy consumption . 15
6.2.2 Battery efficiency . 15
6.2.3 Charger efficiency . 15
Annex A (normative) Determination of battery efficiency by using the synthetic discharge
cycle. 16
A.1 General . 16
A.2 Definition of the synthetic discharge cycle . 16
A.3 Testing according to the synthetic cycle . 17
A.3.1 Preconditions . 17
A.3.2 Power value . 18
A.3.3 Test procedure and measurements. 19
Annex B (normative) Simplified procedure to calculate the battery and charging efficiency
for lead-acid batteries . 21
2

---------------------- Page: 4 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
B.1 General . 21
B.2 Formula . 21
B.2.1 Battery efficiency during discharging based on measurement with constant
discharge current . 21
B.2.2 Estimation of the battery efficiency based on generally accepted empirical values . 21
B.2.3 Charger efficiency . 22
Annex C (informative) Calculation of the Carbon dioxide equivalent . 23
C.1 General . 23
C.2 Calculation of CO equivalent for electric trucks . 23
2
C.3 Calculation of CO equivalent for Diesel powered combustion engine trucks . 23
2
C.4 Calculation of CO equivalent for liquid petroleum gas (LPG) powered combustion
2
engine trucks . 24
C.5 Calculation of CO equivalent for natural gas (CNG) powered combustion engine
2
trucks . 24
Bibliography . 25

3

---------------------- Page: 5 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
European foreword
This document (EN 16796-1:2016) 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 2017, and conflicting national standards shall be
withdrawn at the latest by May 2017.
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CEN shall not be held responsible for identifying any or all such patent rights.
EN 16796 consists of the following parts, under the general title Energy efficiency of Industrial trucks —
Test methods:
— Part 1: General;
— Part 2: Operator controlled self-propelled trucks, towing tractors and burden-carrier trucks;
— Part 3: Container handling lift trucks.
The following parts are under preparation:
— Part 4: Rough-terrain trucks;
— Part 5: Trucks with elevating operator position and trucks specifically designed to travel with elevated
loads.
According to the CEN-CENELEC Internal Regulations, the national standards organisations of the
following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria,
Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia,
France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta,
Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland,
Turkey and the United Kingdom.
4

---------------------- Page: 6 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
Introduction
The EN 16796 series deals with the energy efficiency of industrial trucks and aligns with the New
Approach Ecodesign Directive 2009/125/EC (ErP).
Part 1 contains the procedures to determine the efficiency of trucks, traction batteries and battery
chargers. The other parts provide a specific test cycle for different truck types.
NOTE The test cycles are based on the VDI 2198 guideline. This guideline is widely accepted by industry and
is used to measure the energy consumption of electric industrial trucks and internal combustion industrial trucks.
The guideline is in place since 1996 and it is used broadly. This approach allows the evaluation of the energy
efficiency of trucks by comparison.
The content of this document is of relevance for the following stakeholder groups:
— machine manufacturers (small, medium and large enterprises);
— market surveillance authorities;
— machine users (small, medium and large enterprises);
— service providers, e.g. for consulting activities.
The abovementioned stakeholder groups have been given the opportunity to participate at the drafting
process of this document. The machines concerned are indicated in the Scope of this document.
5

---------------------- Page: 7 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
1 Scope
This European Standard specifies general test criteria and requirements to measure the energy
consumption for self-propelled industrial trucks (hereafter referred to as trucks) during operation. For
electric trucks, the efficiency of the battery and the battery charger is included.
This part of the EN 16796 series is intended to be used in conjunction with the corresponding
EN 16796-2 to -5.
The truck specific requirements in EN 16796-2 to -5 take precedence over the respective requirements
of EN 16796-1.
Of the product life cycle, EN 16796 is applicable to the in-use phase.
It applies to the following truck types according to ISO 5053-1:
— counterbalance lift truck;
— articulated counterbalance lift truck;
— lorry-mounted truck;
— reach truck (with retractable mast or fork arm carriage);
— straddle truck;
— pallet-stacking truck;
— pallet truck;
— platform and stillage truck;
— pallet truck end controlled;
— order-picking truck;
— centre-controlled order-picking truck;
— towing, pushing tractor and burden carrier;
— towing and stacking tractor;
— side-loading truck (one side only);
— rough-terrain truck;
— rough-terrain variable-reach truck;
— slewing rough-terrain variable-reach truck;
— variable-reach container handler;
— counterbalance container handler;
— lateral-stacking truck (both sides);
6

---------------------- Page: 8 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
— lateral-stacking truck (three sides);
— non-stacking low-lift straddle carrier;
— multi-directional lift truck.
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
EN 589, Automotive fuels — LPG — Requirements and test methods
EN 590, Automotive fuels - Diesel - Requirements and test methods
prEN 1459-1, Rough terrain trucks — Safety requirements and verification — Part 1: Variable-reach
trucks
EN 1459-2, Rough-terrain trucks - Safety requirements and verification - Part 2: Slewing variable-reach
trucks
EN 16796 (all parts), Energy efficiency of Industrial trucks — Test methods
EN 60254-1, Lead acid traction batteries - Part 1: General requirements and methods of tests (IEC 60254-
1)
EN ISO 3691-1:2015, Industrial trucks - Safety requirements and verification - Part 1: Self-propelled
industrial trucks, other than driverless trucks, variable-reach trucks and burden-carrier trucks (ISO 3691-
1:2011, including Cor 1:2013)
EN ISO 3691-2, Industrial trucks - Safety requirements and verification - Part 2: Self-propelled variable-
reach trucks (ISO 3691-2)
EN ISO 3691-6, Industrial trucks - Safety requirements and verification - Part 6: Burden and personnel
carriers (ISO 3691-6)
ISO 5053-1:2015, Industrial trucks — Terminology and classification — Part 1: Types of industrial trucks
ISO 15500-1, Road vehicles — Compressed natural gas (CNG) fuel system components — Part 1: General
requirements and definitions
7

---------------------- Page: 9 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
3 Terms and definitions
For the purposes of this document, the terms and definitions given in ISO 5053-1 and the following
apply.
3.1
battery
electrical power source consisting of battery cells, connectors of cells, battery controller (if applicable,
e.g. controller for Li-Ion batteries) and battery enclosure that is ready to use in an industrial truck
3.2
battery state of charge
measured capacity (in Ampere hours [Ah]) of the battery divided by the maximum rated capacity [Ah],
expressed as a percentage
3.3
carbon dioxide equivalent
CDE
quantity that describes, for a given mixture and amount of greenhouse gas, the amount of CO that
2
would have the same global warming potential (GWP)
3.4
charging factor
ratio between amount of Ah recharged into the battery and the prior discharged amount of Ah from the
battery
Note 1 to entry: Typically the charge factor for lead acid batteries is in the range of 1,02 to 1,25.
3.5
cycle time
amount of time it takes a machine to perform a repetitive segment of an operation, typically measured
as the time it takes a machine to return to the same position
3.6
power battery factor
PBF
factor that gives the ratio between the battery capacity and the electrical power taken from the battery
3.7
synthetic discharge cycle
typical battery discharge profile that mirrors the actual energy consumption of electric trucks during a
test cycle
8

---------------------- Page: 10 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
4 Test conditions
4.1 General
The following test conditions ensure that the measurement of power consumption is performed in a
similar and comparable way.
4.2 Test equipment
4.2.1 Test area
The test area shall be a flat and smooth area with a hard, clean and dry surface made of concrete,
asphalt or equivalent. The test course shall have no more than 2 % slope in any direction of travel.
4.2.2 Test track
For truck type specific information for a different truck type see the respective part of EN 16796.
4.2.3 Test load and/or towing capacity
Unless it is otherwise stated in the specific part of EN 16796, the test load shall be equal to 70 % of the
rated load and standard load centre distance of the truck as defined in EN ISO 3691-1, EN ISO 3691-2,
EN 1459-1 or EN 1459-2.
Tractors shall tow with a force according 70 % of the rated drawbar pull as defined in
EN ISO 3691-1:2015, A.3.
Burden-carriers shall be laden with 70 % of the maximum load as defined in EN ISO 3691-6.
4.3 Truck conditions
The truck to be tested shall be a sample that is representative of series production. For all parts of the
truck, with effect to the energy consumption, a run-in time of up to 100 h is permissible. The run-in time
shall be documented.
The truck to be tested shall be in a safe and functional state. All equipment attached shall be in
accordance to the specification of the manufacturer of the truck.
The set-up of the truck (e.g. software parameters) shall be available as per the manufacturer's
specification. That requirement means that the truck performance as specified is achievable (e.g.
driving and lifting speed, acceleration) and all software settings are commercially available to the
customer.
NOTE For instance, the test driver can adapt the maximum driving speed to achieve the cycles / hour.
The test truck shall be fitted with new tyres (max. 10 % of tread wear) which shall comply with the
specifications of the manufacturer of the truck. Pneumatic tyres shall be inflated to their correct
pressure specified by the truck manufacturer or by default from the tire manufacturer.
The fuel tanks of internal combustion engine trucks shall be filled to the maximum specified level prior
to the warm up period. All other tanks shall be filled to their correct operating levels, if applicable.
If the test is to be performed on a sample that is representative for a range of trucks with the same rated
capacity but different lift heights, the test shall be carried out on the truck with the specification
according to EN ISO 3691-1:2015, A.2.1. For trucks covered by prEN 1459-1, EN 1459-2 and
EN ISO 3691-2 see the specific requirements of the applicable part of EN 16796.
For trucks covered by EN ISO 3691-1 the specified lift height shall be at least the standard lift height
according to EN ISO 3691-1:2015, A.2.2. The truck’s specified lift height shall allow the measurement
procedures as defined in the specific part of the EN 16796 series.
9

---------------------- Page: 11 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
If the test is to be performed on a sample that is representative for a range of trucks with the same rated
capacity and the lift height is lower than the lift height that is specified in EN ISO 3691-1:2015, A.2.1 and
A.2.2, the test shall be carried out on the truck with the greatest lift height.
If the test is to be performed on a sample representative of a range of electrical trucks with the option of
different battery capacities the test shall be carried out on the truck with the standard battery/batteries
according to the data sheet of the manufacturer.
4.4 Environmental conditions
The measurement shall be carried out at an environmental temperature range between 10 °C and 30 °C.
The truck in test configuration shall be at operating temperature.
A minimum warm-up period of 10 min is required for the laden truck, before the test starts.
4.5 Truck maintenance
IC-trucks with emissions control systems that may require cleaning or regeneration of the emission
control device shall remain within manufacturer recommended parameters throughout the test. It is
allowed to block automatic regenerating of the emission control device during the test.
Machines with other emissions control systems utilizing additional reagents/materials shall remain
within manufacturers´ recommended parameters throughout the test.
4.6 Battery condition
Battery efficiencies are influenced by many factors e.g. cell technology, cell type, cell design and
geometry. Therefore, the battery efficiency as stated in 6.2.2 is representative for the tested battery
type / battery manufacturer.
If the battery technology requires any energy consuming auxiliary device e.g. battery management
system, controller, cooling or heating, this shall be included in the test.
The battery shall be charged to the rated capacity prior to the respective test. When tests require
discharging to the rated minimum capacity of the battery, this shall be determined by one of the
following methods:
a) Lead-acid batteries voltage:
The battery is discharged if the voltage is less than or equal 1,6 V/cell (according to EN 60254-1 for
discharge current I1).
b) Lead-acid rated capacity:
The battery is discharged if 80 % of the rated capacity is taken from the battery during the test.
Recuperation may be considered by calculating with 75 % of the recuperated current over time.
c) Other technologies:
Discharge criteria are defined by the battery manufacturer. This criterion shall be consistent with
all other specification provided with the battery type e.g. identical life time and life cycle
characteristic based on endurance tests. Dependent on the technology a discharge value given in
energy (Wh) may be used.
10

---------------------- Page: 12 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
5 Measurement procedure
5.1 General
The following clauses are describing the measurement procedure that is applicable for trucks in
general. For specific information for different truck types see the respective part of EN 16796.
5.2 Operating sequence
Trucks shall operate according to the manufacturers' instruction handbook and the test specification
defined in the specific part of EN 16796 with the load according to 4.2.3. Unless it is otherwise stated in
the specific part of the EN 16796 series, pick- and place-cycles may be simulated without depositing the
load.
NOTE The test load can be secured.
The speed shall be so adapted as to obtain the specified number of cycles per hour. Unless it is
otherwise stated in the specific part of EN 16796 simultaneous operations are not permissible, all load
handling and travelling functions shall be operated separately.
For truck types that are not covered exhaustively by a specific part of EN 16796, an appropriate
sequence of operations shall be selected depending on the design in accordance with the intended use
of the truck.
5.3 Electrical trucks
5.3.1 General
To determine the overall energy consumption of electric trucks the test shall consider:
— the overall efficiency of the truck, including motor, controller and electrical installation;
— the efficiency of the battery/batteries;
— the efficiency of the battery charger.
Because the equipment of trucks with batteries and battery chargers is versatile, it is typically
necessary to differ between these elements.
The following clauses are defining the procedure to determine the elements of the system efficiency.
5.3.2 Truck measurement
The battery of the truck shall be charged to the rated capacity prior to the warm-up period.
The measurement of the energy consumption shall start at the first test cycle. The warm-up period shall
be excluded from the measurement.
The energy consumption shall be given in terms of the electrical energy that is required for 1 h
performing the operating sequence, in kWh/h. This measurement can be done by continuous
measurement of voltage and current during the test.
The measurement of voltage and current shall be performed at the connector of the truck and the
traction battery.
T
E = U tf** *I t dt
( ) ( )
truck batt batt
∫
0
where
E Energy taken from the battery during the test in Wh
truck
11

---------------------- Page: 13 ----------------------

SIST EN 16796-1:2017
EN 16796-1:2016 (E)
U Battery voltage in V
batt
I Battery current in A
batt
dt Differential (Measurement over time)
T Test duration
f = 1 for I ≥ 0; and
batt
f = 0,75 for I < 0
batt
NOTE 1 I < 0 represents recuperation. The factor f = 0,75 refers to the majority of traction batteries, namely
batt
lead-acid batteries.
NOTE 2 The factor f differs for other battery technologies, subject to future revisions of this standard.
If the power consumption is determined by measuring electric charge in Ah, the power consumption
shall be calculated by multiplication with the nominal battery voltage.
If the determination of the battery efficiency should be included in the truck measurement procedure,
the measurement cycle shall start with a battery charged to its rated capacity and shall continue until
the battery is discharged to the rated minimum capacity, see 4.6.
5.3.3 Battery efficiency
The battery efficiency consists of two elements that generate power loss:
— the energy flow to the truck (energy taken by the truck from the battery);
— the energy flow from the charger to the battery (energy for complete recharging of the discharged
battery).
NOTE The efficiency varies depending on the battery charging status, the current when discharging, the
current and method when charging, the battery temperature and the battery type.
The overall efficiency of the battery shall be determined by:
— Direct measurement of current and voltage during discharging the battery by performing the truck
measurement according to 5.3.2 until the battery is discharged to the rated minimum capacity, see
last paragraph of 5.3.2
...