New Standards for Fitment of Batteries to Caravans - Electrical Installations Standard (AS/NZS 3001.2:2022)

Background

AS/NZS 3001.2:2022 Electrical installations – Connectable electrical installations and supply arrangements; Part 2: Connectable electrical Installations is a key Australian Standard, covering electrical installations in recreational vehicles (as well as other connectable installations used for accommodation, habitation or commercial purposes).  This Standard has recently undergone a major revision and was published on 18 November 2022.

Caravan Industry Association of Australia holds a seat on the AS/NZS 3001 Standards Australia committee (through Jason Arter) and has worked in collaboration with our member state associations and industry throughout this standard revision project.

The following overview provides a summary of some of the key changes in this revision and is provided as general guidance and information based on our understanding of the electrical Standard requirements.  However, it is important to note that this does not provide an exhaustive list of changes to the standard.  It is strongly recommended that industry businesses make their own investigations and explore the changes to AS/NZS 3001.2:2022 with regard to the recreational vehicles they are producing.  It is also important to ensure that the relevant personnel (e.g. contract or staff electricians, vehicle designers etc.) within your business are up to date with these changes.

There is a significant administration change with the separation of AS/NZS 3001 into 2 parts:

• AS/NZS 3001.1, Electrical installations — Connectable electrical installations and supply arrangements, Part 1: Site supplies for connectable electrical installations
• AS/NZS 3001.2, Electrical installations — Connectable electrical installations and supply arrangements, Part 2: Connectable electrical installations

 

This summary only addresses Part 2 of the Standard (AS/NZS 3001.2) relating to installations within vehicles and relocatable units.

Within Part 2, the Standard has been divided into separate sections that address specific types of connectable electrical installations.  This assists readers to locate the information relevant to their particular installation.  It may mean that a section is not applicable to your installation, depending on the product and features incorporated.

• Section 1 provides the scope, inclusions, and exclusions of this Standard. The definitions and alterations and repairs have been expanded;
• Section 2 provides for the external supply connection and onboard supply installation requirements applicable to a connectable electrical installation;
• Section 3 provides the installation requirements for relocatable units;
• Section 4 provides the installation requirements for recreational vehicles and non-recreational vehicles;
• Section 5 provides the installation requirements for extra-low voltage wiring systems and equipment in all connectable electrical installations; and
• Section 6 provides verification requirements in all connectable electrical installations.

If you are using the Standard for installations in recreational vehicles, refer to sections 1, 2, 4, 5 and 6 - for installations in relocatable units, refer to sections 1,2,3,5 and 6.

 

Key Changes Summary
One of the most significant changes to the Standard is the inclusion of a section outlining requirements for extra-low voltage d.c. electrical installations (Section 5).  Within this section are significant new requirements for batteries, solar panels (and other sources of supply), wiring, electrical equipment and accessories.

 

Batteries
Batteries should be rechargeable and have a minimum battery capacity of 40Ah at a 20h discharge rate.

Securing of batteries – no greater than 25mm movement under a pulling force of twice the battery weight.

Clearance to metallic service lines – 300mm clearance around battery terminals, or appropriate shielding in place.  E.g. to gas, diesel, water lines or similar.

 

Lead-Acid batteries (all types)

• External location:
  • Open to environment or in a vented battery compartment;
  • Must include a spill tray that can hold at least 20% of the electrolyte held by the battery; and
  • Battery compartment vents must be outside the habitable area.
• Internal location:
  • Must be in a battery compartment that is vented to the exterior of the vehicle; and
  • Must include a spill tray that can hold at least 20% of the electrolyte held by the battery.
• Battery compartment ventilation is required via one of three prescribed methods.

 

Lithium ion batteries (all types)

• Location – external to the living area, i.e. behind a wall, compartment or barrier that prevents the ingress of gasses to the habitable area.
• Must be provided with a battery management safety system:
  • Monitors voltage, current and temperature of the battery; and
  • Automatically disconnects for critical conditions.
• Must be provided with a visible monitoring device:
  • Must display state of charge, may display voltage; and
  • May use wired or wireless communication direct to the battery management safety system.
• Installer should consult with the battery manufacturer for compartment design and means of venting that are appropriate for the type of battery.

 

Solar
Renewable energy sources:

• Installed only for charging batteries;
• Only generate extra-low voltage; and
• Must have a device which prevents overcharging of the battery(ies).

Photovoltaic (PV) array installations shall be installed as per this standard (AS/NZS 3001.2).  Further guidance may be sought from AS/NZS 5033.

Overcurrent protection devices shall be provided at the PV array.

PV modules must comply with all national design rules for road safety (i.e. ADRs):

• Height & width limits.
• External projections.
• Vehicle lighting – obstruction.
• Strength of attachment – normal operation, emergency braking, crash scenario.

Recreational vehicle manufacturers who offer solar power systems are strongly encouraged to investigate the full details of the section on solar (and other renewable) energy sources.

 

Multiple sources of supply
An installation may be supplied from multiple sources – either external or on-board, and at either low voltage or extra-low voltage.

A changeover device that ensures only one source of supply can be connected at any given time must be provided on (or adjacent to) the switchboard:

• Where the switchboard is mounted externally, provision is made for the changeover switch to be placed in a prominent position internally; and
• Where a changeover switch is incorporated into a source of supply (e.g. inverter charger) a label shall be placed at the switchboard indicating the location the device.

When multiple sources of supply are present, low voltage socket outlets in the installation must be labelled to indicate the sources of supply.

Onboard Supplies – Inverters
All or part of the electrical installation may be supplied by an on-board source of supply, such as an inverter or inverter charger.

If an inverter (or inverter charger) is fitted:

• Controls must be readily accessible;
• Final sub-circuits supplied by an inverter or inverter charger must be protected by an RCD device. (For an isolated/EPB inverter this can be integral to the unit or external); and
• The main switchboard must contain
  1. A warning label indicating the presence of an inverter; and
  2. A visible indicator showing the status of the inverter or inverter charger – active online or in standby mode.

Note: Where the switchboard is mounted externally, provision is made for these indications to be placed in a prominent position internally.

 

Extra-Low Voltage (12V d.c.) Wiring
Protection must be provided against mechanical damage, environment and other external influences:

• Retention of wiring.
• Enclosure.

Protect must be provided against physical contact with live parts:

• Insulation or physical separation.

Wiring must be suitable for its intended use:

• Current-carrying capacity.
• Voltage drop.
• Conductor size requirements.

Separation must be provided from low voltage (240V) wiring.

Another significant area of change in the standard relates to exclusion areas for electrical equipment and accessories.  Importantly, these restricted areas are applied to both low voltage (240V) and extra-low voltage (e.g. 12V d.c.) equipment and accessories.

 

Exclusion around gas cylinders
The requirements for this area have been aligned with the controlled areas of AS/NZS 5601.2 Gas Installations Standard.

In very broad summary, devices such as switches, motors, appliances cannot be located within a prescribed controlled area around gas cylinders or gas cylinder compartments.

Exceptions are made for electrical fittings and electrical wiring mounted on a drawbar of an RV whose primary function relates to propulsion or roadworthiness of a vehicle.  e.g. trailer plugs, stability controllers, road vehicle lighting.

 

Damp area exclusion zones – showers, external shower (sinks unchanged)
An exclusion zone has been applied around an external shower – similar to internal bathroom requirements.  Again, exceptions are made for equipment whose primary function relates to propulsion or roadworthiness of a vehicle.

Dimensions of the defined zones around an internal shower remain consistent with the previous standards.  Further clarification has been provided to address some of the typical door arrangements seen in current vehicle designs.  e.g. shower doors hinged part way along a door.

 

Cooker exclusion zone
The exclusion zone around an open cooktop has been updated to limit the exclusion area to a height above the cooker as far as the range hood or overhead cupboard (or ceiling if neither of these are applicable).  This is a variation from the corresponding zone in AS/NZS 3000, reducing the area that previously extended up surrounding walls, in recognition of the limited space for relocation of electrical equipment in a recreational vehicle setting.

AS/NZS 3001.2 acts to modify the requirements of AS/NZS 3000 in some key areas:

 

Appliance switching requirements – cooker, A/C, HWS
Appliances are required to be controlled by a switch that is readily identifiable and convenient for its intended use.

This requirement modifies the AS/NZS 3000 requirements relating to isolation switches for air conditioners, hot water services, and cooking appliances, such that these appliances are not required to have separate isolating devices.

 

Switchboard (main circuit breaker) clearances – in a cupboard
The requirements for a switchboard (or main circuit breaker) located in a cupboard have some key clarifications:

• Maximum clearance in front of the switchboard (circuit breaker) is set at 600mm from the face of the device.  note: this modifies AS/NZS 3000 requirements that measure from the edge of an open door in some circumstances;
• Maximum distance from the face of the device to a protruding bench (or another surface) is 600mm; and
• Clearance from the face of a device to the front of the cupboard must be no more than 50mm.

This overview highlights some of the significant changes for consideration within your business.  Further technical bulletins will follow with more detail of some of these changes during the implementation phase of the Standard.

 

Implementation
It is understood that some of the changes outlined in this bulletin may require investigation, design changes and potentially significant lead times to implement, especially in the current business climate.  In recognition of this, a 12-month transition period has been written into the preface, with AS/NZS 3001:2008 remaining current for up to 12 months after the date of publication of the new standard.  After this time, it will be superseded by AS/NZS 3001.1:2022 and AS/NZS 3001.2:2022.

This transition period is welcomed as a practical way to achieve any significant product changes.  However, it is expected that businesses will take steps to adopt the requirements of the new standard as soon as is practicable (and in any case, within the transition period). 

As AS/NZS 3001 is made mandatory by electrical legislation in each State and Territory.  While it is expected that each respective Regulatory Authority will honour the 12-month transitional provision, they may apply the new Standard requirements at an earlier time.  Caravan Industry Association of Australia and your state caravanning associations are working with the respective jurisdictions to confirm the details of transitional arrangements in each State, particularly around the timing for full implementation and enforcement of the new Standard. 

 

Disclaimer:
The information provided in this document is general and is provided in good faith. Readers must make their own investigations or seek specific advice on their particular individual circumstances. Caravan Industry Association of Australia Limited, its employees, contractors and agents are not liable in any way including, without limitation, for negligence, in connection with this document or for any errors in or omissions from this document, or any new understanding of the law whether arising from any legislative instruments or the decision of any court or tribunal, whether before or after this document was prepared, first published, distributed or used.

 

Source - Caravan Industry Accociation of Australia