kSIST FprEN 17003:2021

Road vehicles - Roller brake testers for vehicles of more than 3,5 tons GVW - Safety requirements

This European Standard applies to roller brake testers (brake test benches) designed for roadworthiness tests on categories M2, M3, N2, N3, O3 and O4 vehicles and that might be also used to test M1, N1 categories.
This European Standard covers fixed-bed roller brake testers with or without inspection pits and whose chassis are inside or outside the building.
This European Standard is not covering mobile roller brake testers.
These roller brake testers are fitted to produce measurements for testing and assessing the efficiencies of the brake systems equipping vehicles in the above-cited categories.
The users of the roller brake tester are all kind of staff that for any reason operates the roller brake testers (e.g staff working in public transport, vehicle rental, vehicle maintenance, vehicle repair, training, test laboratories and vehicle inspection sectors,...).
This document is applicable to roller brake testers manufactured 12 months after the date of its publication as EN.

Straßenfahrzeuge - Rollen-Bremsprüfstände für Fahrzeuge mit zulässigem Gesamtgewicht größer als 3,5 Tonnen - Sicherheitsanforderungen

Véhicules routiers - Freinomètres à rouleaux pour véhicules supérieurs à 3,5 t - Exigences de sécurité

Cette norme européenne s'applique aux freinomètres à rouleaux (bancs d'essais de frein) conçu pour des essais de contrôle technique pour les catégories M2, M3, N2, N3, O3 et des véhicules O4 et qui pourraient être aussi utilisé pour tester des catégories M1, N1.
Cette norme européenne couvre des freinomètres à rouleaux encastrés avec ou sans fosses d'inspection et dont les châssis sont à l'intérieur ou à l'extérieur de la construction.
Cette norme européenne ne couvre pas les freinomètres à rouleaux mobiles.
Ces freinomètres à rouleaux sont adaptés pour produire des mesures pour tester et évaluer l'efficacité des systèmes de frein équipant des véhicules dans les catégories citées ci-dessus.
Les utilisateurs du freinomètre à rouleaux sont toute sorte de personnel qui pour une raison quelconque manipule les freinomètres à rouleaux (par exemple le personnel travaillant dans le transport public, la location de véhicule, le maintenance de véhicule, la réparation de véhicule, la formation, les secteurs des essais en laboratoires et de visite des véhicules,...).

Cestna vozila - Valjasti preskuševalniki zavor za vozila z nosilnostjo nad 3,5 t - Varnostne zahteve

General Information

• Status: Not Published
• Public Enquiry End Date: 15-Sep-2016
• ICS: 43.180 - Diagnostic, maintenance and test equipment
• Technical Committee: I13 - Imaginarni 13
• Current Stage: 5020 - Formal vote (FV) (Adopted Project)
• Start Date: 24-Jun-2021
• Due Date: 12-Aug-2021
• Completion Date: 24-Jun-2021
• Directive: 2006/42/EC - Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast)
• Mandate: M/396 - Mandate to CEN and Cenelec for standardisation in the field of machinery
• Ref Project: FprEN 17003 - Road vehicles - Roller brake testers for vehicles of more than 3,5 tons GVW - Safety requirements

Standards Content (sample)

SLOVENSKI STANDARD
oSIST prEN 17003:2016
01-september-2016

Cestna vozila - Valjasti preskuševalniki zavor za vozila z nosilnostjo nad 3,5 t -

Varnostne zahteve

Road vehicles - Roller brake testers for vehicles of more than 3,5 tons GVW - Safety

requirements
Véhicules routiers - Freinomètres à rouleaux pour véhicules supérieurs à 3,5 t -
Exigences de sécurité
Ta slovenski standard je istoveten z: prEN 17003
ICS:
43.180 'LDJQRVWLþQDYGUåHYDOQDLQ Diagnostic, maintenance and
SUHVNXVQDRSUHPD test equipment
oSIST prEN 17003:2016 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

---------------------- Page: 1 ----------------------
oSIST prEN 17003:2016
---------------------- Page: 2 ----------------------
oSIST prEN 17003:2016
DRAFT
EUROPEAN STANDARD
prEN 17003
NORME EUROPÉENNE
EUROPÄISCHE NORM
June 2016
ICS 43.180
English Version
Road vehicles - Roller brake testers for vehicles of more
than 3,5 tons GVW - Safety requirements

This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee

CEN/TC 301.

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, 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.

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: Avenue Marnix 17, B-1000 Brussels

© 2016 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 17003:2016 E

worldwide for CEN national Members.
---------------------- Page: 3 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)
Contents Page

European foreword ....................................................................................................................................................... 4

Introduction .................................................................................................................................................................... 5

1 Scope .................................................................................................................................................................... 6

2 Normative references .................................................................................................................................... 6

3 Terms and definitions ................................................................................................................................... 7

4 Safety requirements for the roller brake testers and/or protective/risk reduction

measures ............................................................................................................................................................ 9

4.1 General ................................................................................................................................................................ 9

4.2 Protection around chassis zone .............................................................................................................. 10

4.2.1 Protection against hazard arising from moving parts .................................................................... 10

4.2.2 Axle presence detection ............................................................................................................................. 10

4.2.3 Access protection to the chassis via the floor, around wheels and rollers ............................. 10

4.2.4 Access protection to the chassis from the inspection pit (if exists) ........................................... 11

4.2.5 Protection on access via the vehicle cabin .......................................................................................... 12

4.3 Control console ............................................................................................................................................. 12

4.3.1 Location ........................................................................................................................................................... 12

4.3.2 Control devices .............................................................................................................................................. 12

4.3.3 Operating mode ............................................................................................................................................ 13

4.3.4 Motors start-up ............................................................................................................................................. 14

4.4 Emergency stop ............................................................................................................................................. 14

4.5 Overview of the safety functions ............................................................................................................ 14

4.6 Electrical equipment ................................................................................................................................... 15

4.6.1 Electrical equipment conformity requirements ............................................................................... 15

4.6.2 Electromagnetic compatibility ................................................................................................................ 15

4.7 Display of safety related information ................................................................................................... 15

4.8 Warning lights ............................................................................................................................................... 16

4.9 Noise ................................................................................................................................................................. 16

5 Verification of the safety specifications and/or preventive measures ..................................... 16

6 Information for use ..................................................................................................................................... 19

6.1 General ............................................................................................................................................................. 19

6.2 General principles for drafting the instructions for use ................................................................ 19

6.2.1 General ............................................................................................................................................................. 19

6.2.2 Contents of the instructions for use ...................................................................................................... 19

6.2.3 Instructions for use ..................................................................................................................................... 20

6.3 Sales documents ........................................................................................................................................... 21

6.4 Marking ............................................................................................................................................................ 21

6.5 Installation instructions ............................................................................................................................ 22

6.5.1 General ............................................................................................................................................................. 22

6.5.2 Installing and dismantling the equipment .......................................................................................... 22

Annex A (informative) Trapping zone ................................................................................................................. 25

Annex B (informative) Definition of the pit hazard zone .............................................................................. 26

B.1 Access protection to the draft shaft from the inspection pit (if exists) .................................... 26

B.1.1 Description of hazardous phenomena ................................................................................................. 26

---------------------- Page: 4 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)

B.1.2 Consideration ................................................................................................................................................. 26

B.1.3 Three installation types ............................................................................................................................. 26

B.1.4 Specific cases .................................................................................................................................................. 28

Annex C (informative) Access protection to moving parts from the inspection pit (if exists) ......... 32

C.1 General ............................................................................................................................................................. 32

C.2 Protection by light curtain ........................................................................................................................ 32

C.3 Protection by a fixed covering guard ..................................................................................................... 34

Annex D (informative) Examples of access protection to the chassis via the floor, around

wheels and rollers ........................................................................................................................................ 36

D.1 General ............................................................................................................................................................. 36

D.2 Opto-electronic device ................................................................................................................................ 36

Annex E (informative) Determination of PL ..................................................................................................... 40

E.1 General ............................................................................................................................................................. 40

E.2 Axle presence detection function ........................................................................................................... 40

E.3 Pit presence detection function ............................................................................................................... 40

E.4 Failsafe mode selector ................................................................................................................................ 40

E.5 Calibration mode selector ......................................................................................................................... 41

E.6 Emergency stop ............................................................................................................................................. 41

Annex F (normative) Noise and gas emission ................................................................................................... 42

F.1 Noise .................................................................................................................................................................. 42

F.1.1 Noise of the roller brake tester ................................................................................................................ 42

F.1.2 Noise from the tested vehicle ................................................................................................................... 42

F.2 Gas emission from the tested vehicle .................................................................................................... 42

Annex G (informative) List of significant hazards ............................................................................................ 43

Annex ZA (informative) Relationship between this European Standard and the Essential

Requirements of EU Directive (Directive 2006/42/EC OF THE EUROPEAN
PARLIAMENT AND OF THE COUNCIL of 17 May 2006 on machinery, and amending

Directive 95/16/EC (recast)) ................................................................................................................... 46

Bibliography ................................................................................................................................................................. 49

---------------------- Page: 5 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)
European foreword

This document (prEN 17003:2016) has been prepared by Technical Committee CEN/TC 301 “Road

vehicles”, the secretariat of which is held by AFNOR.
This document is currently submitted to the CEN Enquiry.

This document has been prepared under a mandate given to CEN by the European Commission and the

European Free Trade Association, and supports essential requirements of EU Directive.

For relationship with EU Directive, see informative Annex ZA, which is an integral part of this

document.
---------------------- Page: 6 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)
Introduction
This document is a type C standard as stated in EN ISO 12100:2010.

The machinery concerned and the extent to which hazards, hazardous situations and hazardous events

are covered are indicated in the scope of this document. In addition, machinery should comply as

appropriate with EN ISO 12100 for hazards which are not covered by this standard.

When provisions of this type C standard are different from those which are stated in type A or B

standards, the provisions of this type C standard take precedence over the provisions of the other

standards, for machines that have been designed and built according to the provisions of this type C

standard.

The object of this European Standard is to define rules for safeguarding persons against the risk of

accidents associated with the operation of roller brake testers.

While elaborating this standard it was assumed that only authorized persons operate the roller brake

testers.
---------------------- Page: 7 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)
1 Scope

This European Standard applies to roller brake testers (brake test benches) designed for

roadworthiness tests on categories M2, M3, N , N3, O3 and O4 vehicles and that might be also used to

test M1, N1 categories.

This European Standard covers fixed-bed roller brake testers with or without inspection pits and whose

chassis are inside or outside the building.
This European Standard is not covering mobile roller brake testers.

These roller brake testers are fitted to produce measurements for testing and assessing the efficiencies

of the brake systems equipping vehicles in the above-cited categories.

The users of the roller brake tester are all kind of staff that for any reason operates the roller brake

testers (e.g staff working in public transport, vehicle rental, vehicle maintenance, vehicle repair,

training, test laboratories and vehicle inspection sectors, …).

This document is applicable to roller brake testers manufactured 12 months after the date of its

publication as EN.
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 614-1, Safety of machinery — Ergonomic design principles — Part 1: Terminology and general

principles

EN 614-2, Safety of machinery — Ergonomic design principles — Part 2: Interactions between the design

of machinery and work tasks

CEN/TR 614-3, Safety of machinery — Part 3: Ergonomic principles for the design of mobile machinery

EN 953, Safety of machinery — Guards — General requirements for the design and construction of fixed

and movable guards

EN 12464-1, Light and lighting — Lighting of work places — Part 1: Indoor work places

EN 60204-1, Safety of machinery — Electrical equipment of machines — Part 1: General requirements

(IEC 60204-1)

EN 61000-6-2, Electromagnetic compatibility (EMC) — Part 6-2: Generic standards — Immunity for

industrial environments (IEC 61000-6-2)

EN 61000-6-3, Electromagnetic compatibility (EMC) — Part 6-3: Generic standards — Emission standard

for residential, commercial and light-industrial environments (IEC 61000-6-3)

EN ISO 12100:2010, Safety of machinery — General principles for design — Risk assessment and risk

reduction (ISO 12100:2010)

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

principles for design (ISO 13849-1)

EN ISO 13850, Safety of machinery — Emergency stop function — Principles for design (ISO 13850)

---------------------- Page: 8 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)

EN ISO 13855, Safety of machinery — Positioning of safeguards with respect to the approach speeds of

parts of the human body (ISO 13855)

EN ISO 13857:2008, Safety of machinery — Safety distances to prevent hazard zones being reached by

upper and lower limbs (ISO 13857:2008)
3 Terms and definitions

For the purposes of this document, the terms and definitions given in EN ISO 12100 and the following

apply.
3.1
roller brake tester or roller brake test bench

system fitted to produce measurements for testing and assessing the efficiencies of vehicle brake

system

Note 1 to entry: There are also plate roller brake testers that are not covered under this standard.

3.2
brake tester
term that, in this standard, refers to roller brake tester (or brake test bench)
3.3
chassis

term that, in this standard, refers to embedded or mounted mechanical floor units comprising the

measuring rollers, drive and gearbox motors, and measuring devices, and that carry the wheel or axle

under test
3.4
fixed-bed control console

console that features at minimum the human-machine interface: display, control devices, data storage

3.5
secondary (screen) display

fixed-bed or movable device that duplicates test-related information but without offering any control

action
3.6
remote control
remote control which is used to navigate the human-machine interface at distance
3.7
electrical box

box which provides the interface between the control console and the chassis, which may be integrated

into the fixed-bed control console and which comprises at least:
— the main switch;
— the motor control devices;
— electrical safety components
---------------------- Page: 9 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)
3.8
wheel presence sensor

term used for a sensor whose function is to provide guaranteed confirmation that a wheel is detected as

safely located in the rollers, in compliance with the test conditions required

Note 1 to entry: The axle weight measurement can be used to confirm the reading or to detect a presence

detection device failure.
3.9
inspection pit

cavity dug into the floor, and in which a technician stands inside to inspect the under-vehicle

Note 1 to entry: There are also brake testers without pit.

Note 2 to entry: Many two-block chassis are installed on either side of an inspection pit, enabling access under

the vehicle.
3.10
active opto-electronic protective device
AOPD

device whose sensing function is performed by opto-electronic emitting and receiving elements

detecting the interruption of any optical radiation generated, within the device, by an opaque object

present in the specified detection zone (or for a light beam device, on the axis of the light beam)

[SOURCE: EN 61496-2:2013, 3.201, modified — "optical radiations" is replaced here with "any optical

radiation".]
3.11
light curtain

AOPD comprising an integrated assembly of one or more emitting element(s) and one or more receiving

element(s) forming a detection zone with a detection capability specified by the supplier

Note 1 to entry: A light curtain with a large detection capability is sometimes referred to as a light grid.

[SOURCE: EN 61496-2:2013, 3.205]
3.12
enabling device

additional manually-operated device used in conjunction with a start control and which, when

continuously actuated, allows a machine to function
[SOURCE: EN ISO 12100:2010, 3.28.2]
3.13
brake tester trapping zone

zone at the interface between a wheel of the axle under test and the brake tester rollers spinning in

opposite direction, towards the closest generatrix

Note 1 to entry: The trapping zone creates a draw-in and crushing hazard (see the informative Annex A).

Note 2 to entry: The trapping zone is sometimes called angle or re-entrant point.

3.14
operator
person performing test sequences
---------------------- Page: 10 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)
3.15
driver

person who drives the vehicle during the test sequences who may be also the operator

3.16
mobile control console

control console that features at minimum the human-machine interface: display, control devices, data

storage and which is movable
3.17
hazard zone

space within and/or around machinery in which a person can be exposed to a hazard

[SOURCE: EN ISO 12100:2010, 3.11]
3.18
no-trespassing area

area with permanent fully marked surface (yellow & black) on the ground, and where access is

prohibited during vehicle test
4 Safety requirements for the roller brake testers and/or protective/risk
reduction measures
4.1 General

The machinery shall comply with the requirements and/or preventive measures of this clause.

In addition, the machinery shall be designed according to the principles of EN ISO 12100 for relevant

hazards but non-significant hazards, which are not dealt with in this document.

Safety devices shall ensure that the risk of an intrusion in a trapping zone and/or contact with moving

parts (from brake tester and vehicle moving parts, such as drive shaft, put in movement by the roller

brake tester) is reduced to the lowest possible level.

During the functioning of the machinery, in case of a chassis fitted on an inspection pit, they shall

prevent or detect access to the area under the floor level close to the bench to prevent contact with the

moving parts of the machinery and the vehicle under test.

If a safety device stops the brake tester running, the system shall be only re-engaged by a voluntary

action from the operator on a control device of the roller brake tester. The automatic restart of the

system after a stop caused by a safety device shall not be possible under any circumstances.

Safety devices shall be designed in a way to authorize the test bench motor start and control the stop,

keeping into account the possibility of stops by unintended response of the safety device (e.g. by dust,

snow or smoke, by slightly moving vehicle, by sensor cables). The option of operating the machinery

without the vehicle and with the safety devices disabled shall be only foreseen for maintenance and

calibration operations, with dedicated procedures carried out only by trained personnel, as foreseen at

Subclauses 4.3.3.4 and 4.3.3.5 and subsequent. If possible, the condition and use of safety devices

should be registered on IT support.

Safety devices necessary for the safe functioning of the roller brake tester shall be considered part of

the machinery itself. In some cases, as the correct functioning of safety devices can depend on specific

installation conditions, the characteristic of such devices shall be evaluated according to the specifics of

the installation.

All safety devices which control the start-up and/or emergency-stop of the motors (Stop Category 0 or

Category 1 under EN 60204-1) shall deliver performance level according to Table 1 (see 4.5).

---------------------- Page: 11 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)

If safety devices are not able to eliminate every risk completely, then residual risks shall be underlined

and adequately managed in the user manual.

Before putting the roller brake tester into service, the manufacturer or his authorized representative

(or in specific case the installer) shall:

a) ensure that it satisfies the relevant essential health and safety requirements;

b) ensure that the technical file is available;
c) provide, in particular, the necessary information, such as instructions;

d) carry out the appropriate procedures for assessing conformity according to the manufacturer's

prescription;

e) draw up the EC declaration of conformity and ensure that it accompanies the machinery;

f) affix the CE marking.
4.2 Protection around chassis zone
4.2.1 Protection against hazard arising from moving parts

The chassis shall be designed in such a way as to make it impossible to access internal moving parts

(drive chains, gears).
The guard shall be designed according to EN 953.
4.2.2 Axle presence detection

Each side of the roller brake tester shall be fitted with a wheel presence sensor. The 2-wheel presence

sensors shall be simultaneously activated to allow the bench to start.

The axle presence detection device shall prohibit the roller brake tester to start in case of axle lack and

shall interrupt roller brake tester operation if axle presence information is lost.

If the roller brake tester is equipped with weight measurement, a crosscheck with the presence

detection can be used to detect a sensor failure.
The system shall deliver a PL = c.
4.2.3 Access protection to the chassis via the floor, around wheels and rollers

The chassis shall be provided with appropriate means to prevent any unintentional entrance inside the

no-trespassing area.

The lateral access to the chassis via the floor, around wheels and rollers shall be prevented by barriers.

If there is a free access way of at least 800 mm wide, 2 physical barriers shall be designed and installed

accordingly to EN ISO 13857 on each side of the bench. These 2 safeguards shall have a height of 1,40 m

and a minimum total length of 3 m centred on the mid-axle of the rollers.

The risk of front and rear access to the chassis shall be managed by (at least) signalling the no-

trespassing area using adequate visual elements like stripes on the floor, warning lights, and similar

(see Figure 1).

The no-trespassing area shall be at least the area delimited by the physical barriers.

---------------------- Page: 12 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)
Key
a area of danger identified with the area of the rollers
b safety device. Physical lateral barriers
c no-trespassing area
d lamp with emission light yellow flashing with the rotation of the rollers
Figure 1 — Surface protection

In the case of an installation to replace a roller brake tester in an existing installation pit which is

located closer than 800 mm from a wall then specific equivalent provisions shall be taken to prevent

access to the area between the roller brake tester and the wall.
4.2.4 Access protection to the chassis from the inspection pit (if exists)

When the roller brake tester is fitted on an inspection pit or close to an inspection pit, then the rotation

of the rollers shall be stopped or prevented from starting in case of access to the hazard zone from the

inspection pit to prevent the presence of persons in dangerous areas of the rotating drive shafts, the

vehicle wheels, or the rollers of the test bench.

For a roller brake tester stopping time of 0,8 s max then the protection distance before the bench from

the top of the first roller shall be minimum 2,4 m and 5,0 m after the bench from the top of the second

roller.

The design of all auxiliary equipment, like air pressure sensors, should be compatible with the use of

the safety device.
In the Informative Annex C, examples of solutions are given.
In case of use of detection devices, they shall be compliant with EN ISO 13855.
The system shall deliver a PL = d.
---------------------- Page: 13 ----------------------
oSIST prEN 17003:2016
prEN 17003:2016 (E)
Figure 2 — Protection distance geometry
4.2.5 Protection on access via the vehicle cabin

For the access from the cabin to the hazard zone, without available measures for protection, the risk is

residual and shall be underli
...