ISO/PRF TS 4210-10

TECHNICAL ISO/TS SPECIFICATION 4210-10 First edition Cycles — Safety requirements for bicycles — Part 10: Safety requirements for electrically power assisted cycles (EPACs) PROOF/ÉPREUVE Reference number ISO/TS 4210-10:2020(E) ISO 2020 ---------------------- Page: 1 ---------------------- ISO/TS 4210-10:2020(E) COPYRIGHT PROTECTED DOCUMENT © ISO 2020

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Foreword ..........................................................................................................................................................................................................................................v

Introduction ................................................................................................................................................................................................................................vi

1 Scope ................................................................................................................................................................................................................................. 1

2 Normative references ...................................................................................................................................................................................... 1

3 Terms and definitions ..................................................................................................................................................................................... 2

4 Abbreviated terms .............................................................................................................................................................................................. 5

5 General requirements ..................................................................................................................................................................................... 6

5.1 Lighting systems, reflectors and warning device ...................................................................................................... 6

5.2 Risk assessment ..................................................................................................................................................................................... 7

5.3 Significant hazards and safety functions .......................................................................................................................... 7

5.3.1 Significant hazards ......................................................................................................................................................... 7

5.3.2 Safety function for control system of EPACs ............................................................................................ 7

5.4 Prevention of unauthorized use ............................................................................................................................................... 8

5.5 Failure mode ............................................................................................................................................................................................. 8

5.5.1 Requirement ........................................................................................................................................................................ 8

5.5.2 Test method .......................................................................................................................................................................... 8

6 Electrical requirements ................................................................................................................................................................................ 8

6.1 Motor controller .................................................................................................................................................................................... 8

6.2 Controls and symbols ........................................................................................................................................................................ 8

6.3 Batteries ........................................................................................................................................................................................................ 9

6.4 Battery charger ....................................................................................................................................................................................... 9

6.4.1 Requirements for proprietary system ........................................................................................................... 9

6.4.2 Requirements for non-proprietary system ............................................................................................... 9

6.4.3 Solutions for non-proprietary systems .....................................................................................................10

6.5 Electric cables and couplers .....................................................................................................................................................10

6.6 Wiring ..........................................................................................................................................................................................................10

6.7 Protection against ingress of water (IP code) ...........................................................................................................11

6.8 Environmental and operational conditions ................................................................................................................11

6.9 Mechanical strength of the electrical components ...............................................................................................11

6.9.1 General...................................................................................................................................................................................11

6.9.2 Function related shock test..................................................................................................................................11

6.9.3 Impact related shock test ......................................................................................................................................11

6.10 Performance measurement.......................................................................................................................................................12

6.10.1 General...................................................................................................................................................................................12

6.10.2 System based on maximum continuous rated power ...................................................................12

6.10.3 System based on maximum assisted rate ................................................................................................14

6.11 Walk assistance mode ....................................................................................................................................................................20

6.11.1 Requirements ..................................................................................................................................................................20

6.11.2 Test method for EPAC with walk assistance mode ..........................................................................20

6.12 Electromagnetic Compatibility (EMC) .............................................................................................................................21

6.12.1 Requirement .....................................................................................................................................................................21

6.13 Anti-tampering measure .............................................................................................................................................................21

6.13.1 General...................................................................................................................................................................................21

6.13.2 Prevention of tampering of the motor .......................................................................................................21

6.14 Thermal hazards .................................................................................................................................................................................22

6.14.1 Non-continuous contact surface .....................................................................................................................22

6.14.2 Continuous contact surface .................................................................................................................................22

6.14.3 Ambient temperature ...............................................................................................................................................22

7 Mechanical requirements ........................................................................................................................................................................22

7.1 General ........................................................................................................................................................................................................22

7.2 Brakes — Heat-resistance test ...............................................................................................................................................22

7.3 Handlebar and stem assembly — Lateral bending test ....................................................................................22

7.4 Handlebar stem — Forward bending test ....................................................................................................................23

7.5 Handlebar to handlebar stem — Torsional security test ................................................................................23

7.6 Handlebar and stem assembly — Fatigue test .........................................................................................................23

7.7 Frame — Impact test (falling mass) ..................................................................................................................................23

7.8 Frame and front fork assembly — Impact test (falling frame) ...................................................................24

7.9 Frame — Fatigue test with horizontal forces ............................................................................................................24

7.10 Frame — Fatigue test with a vertical force ..................................................................................................................24

7.11 Front fork — Static bending test ..........................................................................................................................................25

7.12 Front fork — Rearward impact test ...................................................................................................................................25

7.13 Front fork — Bending fatigue test plus rearward impact test ....................................................................25

7.14 Seat-post — Fatigue test ..............................................................................................................................................................25

8 Manufacturer's instructions ..................................................................................................................................................................26

9 Marking .......................................................................................................................................................................................................................26

Annex A (normative) Electromagnetic compatibility of EPACs ..............................................................................................28

Annex B (informative) Electromagnetic compatibility of ESAs ..............................................................................................35

Annex C (normative) The battery chargers for non-proprietary system ....................................................................44

Annex D (normative) Light, audible warning device, On/Off symbols .......................................................................118

Annex E (informative) Environmental and operational conditions ..............................................................................119

Annex F (normative) Battery .................................................................................................................................................................................120

Bibliography .........................................................................................................................................................................................................................125

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different types of ISO documents should be noted. This document was drafted in accordance with the

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This document was prepared by Technical Committee ISO/TC 149, Cycles, Subcommittee SC 1, Cycles

Any feedback or questions on this document should be directed to the user’s national standards body. A

This document combines several countries’ safety requirements for Electrically Power Assisted Cycles

(EPACs). The commercialization of EPACs has accelerated in the global market, in response to global

concerns about CO reduction and energy saving. EPAC technologies for performance, electrical control,

battery management and battery charging are currently developing rapidly in a competitive market. It

is therefore necessary to standardize the safety of these technologies for EPACs.

This documentation will allow an easy and clear understanding of requirements for different types

This document includes safety requirements for the charging of EPACs. This includes off-board parts

This document does not state the limit for the maximum permissible load of the EPAC. The manufacturer

is advised to consider amongst other factors the maximum permissible load (luggage plus rider) as well

as the intended use of the EPAC. Both have an influence on the mechanical requirements.

This document specifies safety and performance requirements for the design, marking, assembly, and

testing of two wheeled electrically power assisted cycles (hereafter EPACs), fully-assembled EPACs and

subassemblies, and provides guidelines for information supplied by the manufacturers (i.e. instructions

This document applies to two wheeled EPACs that have a maximum saddle height of 635 mm or more

and are intended for private and commercial use with exception of EPACs intended for hire from

This document is intended to cover all common significant hazards, hazardous situations and events

listed in 5.3 of EPACs, when used as intended or under conditions of misuse that are reasonably

This document specifies requirements and test methods for engine power management systems,

electrical circuits including the charger for the assessment of the design and assembly of EPACs and

sub-assemblies for systems having a Safety Extra Low Voltage (SELV) maximum voltage up to 60 V d.c.

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.

ISO 4210-1, Cycles — Safety requirements for bicycles — Part 1: Terms and definitions

ISO 4210-2:2015, Cycles — Safety requirements for bicycles — Part 2: Requirements for city and trekking,

ISO 4210-4:2014, Cycles — Safety requirements for bicycles — Part 4: Braking test methods

ISO 4210-5:2014, Cycles — Safety requirements for bicycles — Part 5: Steering test methods

ISO 4210-6:2015, Cycles — Safety requirements for bicycles — Part 6: Frame and fork test methods

ISO 4210-9:2014, Cycles — Safety requirements for bicycles — Part 9: Saddle and seat-post test methods

ISO 7010:2011, Graphical symbols — Safety colours and safety signs — Registered safety signs

ISO 11451-1, Road vehicles — Vehicle test methods for electrical disturbances from narrowband radiated

ISO 11451-2, Road vehicles — Vehicle test methods for electrical disturbances from narrowband radiated

ISO 11452-1, Road vehicles — Component test methods for electrical disturbances from narrowband

ISO 11452-2, Road vehicles — Component test methods for electrical disturbances from narrowband

ISO 11452-4:2011, Road vehicles — Component test methods for electrical disturbances from narrowband

ISO 11898-1, Road vehicles — Controller area network (CAN) —Part 1: Data link layer and physical

ISO 11898-2, Road vehicles — Controller area network (CAN) —Part 2: High-speed medium access unit

ISO 12100, Safety of machinery — General principles for design — Risk assessment and risk reduction

ISO 13849-1, Safety of machinery — Safety-related parts of control systems — Part 1: General principles

ISO 13849-2, Safety of machinery — Safety-related parts of control systems — Part 2: Validation

IEC 60068-2-27, Environmental testing — Part 2-27: Tests — Test Ea and guidance: Shock

IEC 60335-2-29, Household and similar electrical appliances — Safety — Part 2-29: Particular requirements

IEC 62133-1:2017, Secondary cells and batteries containing alkaline or other non-acid electrolytes — Safety

requirements for portable sealed secondary cells, and for batteries made from them, for use in portable

IEC 62133-2:2017, Secondary cells and batteries containing alkaline or other non-acid electrolytes —

Safety requirements for portable sealed secondary lithium cells, and for batteries made from them, for use

CISPR 12:2007 + A1: 2009, Vehicles, boats and internal combustion engines — Radio disturbance

characteristics — Limits and methods of measurement for the protection of off-board receivers

CISPR 16-1-1:2015, Specification for radio disturbance and immunity measuring apparatus and methods —

Part 1-1: Radio disturbance and immunity measuring apparatus — Measuring apparatus

CISPR 25:2016, Vehicles, boats and internal combustion engines — Radio disturbance characteristics —

EN 50604-1:2016, Secondary lithium batteries for light EV (electric vehicle) applications — Part 1: General

For the purposes of this document, the terms and definitions given in ISO 4210-1 and the following apply.

ISO and IEC maintain terminological databases for use in standardization at the following addresses:

any vehicle which has at least two wheels and is propelled by the muscular energy of the person on that

vehicle, in particular by means of pedalling or the possibility of adding assistance provided by electric

Note 1 to entry: Pedalling also refers to use of hand cranks or other similar devices.

cycle (3.1), equipped with pedals and an auxiliary electric motor, which cannot be propelled exclusively

electrically power assisted cycle (3.2) designed for use off-road on rough terrain, on public roads, and on

public pathways, equipped with a suitably strengthened frame and other components, and, typically,

with wide-section tyres with coarse tread patterns and a wide range of transmission gears

[SOURCE: ISO 4210-1:2014, 2.30, modified — bicycle has been changed to electrically power

output power specified by manufacturer, at which the motor reaches its thermal equilibrium at given

speed at which the motor controller cuts off the assistance of the auxiliary electric motor

function by which the user can activate the auxiliary electric motor to propel the EPAC up to a defined

ability of an EPAC or one of its electrical/electronic systems to function satisfactorily in its

electromagnetic environment without introducing intolerable electromagnetic disturbance to anything

[SOURCE: IEC 60050-161:1990/AMD8: 2018, IEV ref. 161-01-07, modified — an EPAC or one of its

electronic and/or electrical component, or an assembly of components provided for installation into

an EPAC, together with all electrical connections and associated wiring for the execution of several

device or group of devices that serves to govern in some predetermined manner the performance of an

Note 1 to entry: Means for manual or automatic ON/OFF, selecting the drive direction, regulating the speed,

local energy management system for the battery system, protecting the battery system from damage,

Note 1 to entry: BMS and BCU (according to ISO 12405) do not have the same functions.

emission which has a bandwidth less than that of a specific receiver or measuring instrument

current measured at battery output with no change to the operating status of any auxiliary systems

voltage not exceeding ripple-free 60 V d.c. between conductors and earth, the no load voltage not

technical requirements and specifications which prevent, as far as possible, unauthorized modifications

[SOURCE: IEC 60050-714:1990, IEV ref. 714-03-04, this source is only for “inlet”]

[SOURCE: IEC 60050-151:2001, IEV ref. 151-12-19, this source is only for “connector”]

seat-post that cannot be raised or lowered independently of the seat tube clamp, while riding, and does

not provide controlled axial flexibility to reduce the transmission of road shocks to the rider.

seat-post incorporating controlled, axial flexibility to reduce the transmission of road shocks to the rider

seat-post that can be raised or lowered independently of the seat tube clamp while riding

seat-post incorporating controlled, axial flexibility to reduce the transmission of road shocks to the

rider and incorporating the capability of raising and lowering independently of the seat tube clamp