IEC 62840-2:2025
(Main)Electric vehicle battery swap system - Part 2: Safety requirements
Electric vehicle battery swap system - Part 2: Safety requirements
IEC 62840-2:2025 provides the safety requirements for a battery swap system, for the purposes of swapping swappable battery system (SBS)/handheld-swappable battery system (HBS) of electric vehicles. The battery swap system is intended to be connected to the supply network. The power supply is up to 1 000 V AC or up to 1 500 V DC in accordance with IEC 60038. This document also applies to battery swap systems supplied from on-site storage systems (e.g. buffer batteries).
Aspects covered in this document:
• safety requirements of the battery swap system and its systems;
• security requirements for communication;
• electromagnetic compatibility (EMC);
• marking and instructions;
• protection against electric shock and other hazards.
This document is applicable to battery swap systems for EV equipped with one or more SBS/HBS.
This document is not applicable to
• aspects related to maintenance and service of the battery swap station (BSS),
• trolley buses, rail vehicles and vehicles designed primarily for use off-road, and
• maintenance and service of EVs.
Requirements for bidirectional energy transfer are under consideration
This second edition cancels and replaces the first edition published in 2016. This edition constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous edition:
a) expands the scope to encompass both swappable battery systems (SBS) and handheld swappable battery systems (HBS);
b) introduces stricter interoperability requirements through detailed system interface specifications and defined state transition protocols;
c) enhances data security by defining safety message transmission protocols and integrating telecom network requirements;
d) increases electrical safety protection levels for battery swap stations (BSS) with specified capacitor discharge time limits to mitigate electric shock risks;
e) introduces enhanced mechanical safety requirements for automated battery handling systems, with technical alignment to ISO 10218-1 and ISO 10218-2;
f) strengthens overload and short-circuit protection for BSS through standardized testing methods and overcurrent protection specifications;
g) defines upgraded electromagnetic compatibility (EMC) standards to ensure system resilience against external interference, supplemented with EMC-related functional safety measures.
This document is to be read in conjunction with IEC 62840-1:2025.
Système d'échange de batterie de véhicule électrique - Partie 2: Exigences de sécurité
L'IEC 62840-2:2025 spécifie les exigences de sécurité relatives à un système d’échange de batterie, afin de remplacer le système de batterie échangeable (SBS)/le système de batterie échangeable portative (HBS) des véhicules électriques. Le système d’échange de batterie est destiné à être connecté au réseau électrique. L’alimentation atteint 1 000 V en courant alternatif ou 1 500 V en courant continu, conformément à l’IEC 60038. Le présent document s’applique également aux systèmes d’échange de batterie alimentés par des systèmes de stockage sur site (par exemple, des batteries tampons).
Le présent document traite des aspects suivants:
• les exigences de sécurité du système d’échange de batterie et de ses sous-systèmes;
• les exigences de sûreté de la communication;
• la compatibilité électromagnétique (CEM);
• le marquage et les indications;
• la protection contre les chocs électriques et autres phénomènes dangereux.
Le présent document s’applique aux systèmes d’échange de batterie pour les VE équipés d’un ou de plusieurs SBS/HBS.
Le présent document ne concerne pas:
• les aspects liés à la maintenance et à l’entretien de la station d’échange de batterie (BSS);
• les trolleys bus, véhicules ferroviaires et véhicules destinés principalement à une utilisation tout terrain; et
• la maintenance et l’entretien des VE.
Les exigences relatives au transfert d’énergie bidirectionnel sont à l’étude.
Cette deuxième édition annule et remplace la première édition parue en 2016. Cette édition constitue une révision technique.
Cette édition inclut les modifications techniques majeures suivantes par rapport à l’édition précédente:
a) extension du domaine d’application pour englober à la fois les systèmes de batteries échangeables (SBS, Swappable Battery System) et les systèmes de batteries échangeables portatives (HBS, Handheld swappable Battery System);
b) introduction d’exigences d’interopérabilité plus strictes par le biais de spécifications d’interface système détaillées et de protocoles définis pour le passage entre les différents états;
c) renforcement de la sûreté des données en définissant des protocoles de transmission des messages de sécurité et en intégrant les exigences des réseaux de télécommunications;
d) augmentation des niveaux de protection de sécurité électrique pour les stations d’échange de batteries (BSS, Battery Swap Station), par le biais de limites spécifiées de temps de décharge des condensateurs, afin d’atténuer les risques de choc électrique;
e) introduction d’exigences de sécurité mécanique renforcées pour les systèmes automatisés de manutention des batteries, avec un alignement technique sur l’ISO 10218-1 et l’ISO 10218-2;
f) renforcement de la protection des BSS contre les surcharges et les courts-circuits, au moyen de méthodes d’essai normalisées et de spécifications de protection contre les surintensités;
g) définition de normes de compatibilité électromagnétique (CEM) améliorées pour assurer la résilience du système aux perturbations externes, complétées par des mesures de sécurité fonctionnelle liées à la CEM.
General Information
Relations
Standards Content (Sample)
IEC 62840-2 ®
Edition 2.0 2025-07
INTERNATIONAL
STANDARD
COMMENTED VERSION
Electric vehicle battery swap system -
Part 2: Safety requirements
ICS 43.120 ISBN 978-2-8327-0567-4
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CONTENTS
FOREWORD . 4
INTRODUCTION . 7
1 Scope . 8
2 Normative references . 8
3 Terms and definitions . 11
4 Abbreviated terms . 13
5 General requirements . 13
6 Classification . 14
7 Safety requirements of systems . 14
7.1 General . 14
7.2 Lane system . 14
7.2.1 Vehicle lane . 14
7.2.2 Measures in case of emergency . 15
7.3 Battery handling system . 15
7.3.1 Interlock protection guarding . 15
7.3.2 Interlock with the lane . 15
7.3.3 Battery handling process . 15
7.3.4 Measures in case of emergency . 16
7.4 Storage system . 17
7.4.1 Battery storage . 17
7.4.2 Measures in case of emergency . 18
7.5 Charging system . 18
7.5.1 SBS/HBS charger . 18
7.5.2 Charger connection . 19
7.5.3 Charging rack . 19
7.5.4 Communication and monitoring . 19
7.6 Swappable battery system SBS/HBS . 20
7.6.1 General . 20
7.6.2 Interoperability requirements . 20
7.7 Supervisory and control system . 20
7.8 Supporting systems . 21
7.8.1 Battery maintenance system . 21
7.8.2 SBS/HBS logistic system . 21
7.9 Power supply system . 22
7.10 Interfaces. 22
8 Communication . 22
8.1 Data security . 22
8.2 Transmission of safety related messages . 22
8.3 Telecommunication network . 22
9 Protection against electric shock . 22
9.1 General requirements . 22
9.2 Protection against direct contact Provisions for basic protection . 23
9.2.1 IP degrees for the enclosures shock prevention . 23
9.2.2 IP degrees for coupler . 24
7.2.3 Bidirectional energy transfer .
9.2.3 Stored energy – discharge of capacitors . 24
9.3 Fault protection . 24
9.4 Protective conductor . 24
9.5 Supplementary measures. 25
9.5.1 Additional protection . 25
9.5.2 Manual/automatic reset . 25
9.5.3 Protection of persons against electric shock . 25
7.7 Telecommunication network .
10 Specific requirements for accessories. 26
11 Cable assembly requirements . 26
12 Equipment BSS constructional requirements . 26
12.1 General . 26
12.2 Characteristics of mechanical switching devices . 26
12.2.1 Switch and switch-disconnector . 26
12.2.2 Contactor . 26
12.2.3 Circuit-breaker . 27
12.2.4 Relays . 27
12.2.5 Metering . 27
12.2.6 Switch-on peak current/Inrush current . 27
12.3 Clearances and creepage distances. 27
12.4 IP degrees for the penetration . 27
12.5 Insulation resistance . 28
12.6 Touch current . 28
12.7 Dielectric withstand voltage . 29
12.7.1 AC withstand voltage . 29
12.7.2 Impulse dielectric withstand (1,2 µs/50 µs) . 29
12.8 Temperature rise . 29
12.9 Damp heat functional test . 29
12.10 Minimum temperature functional test . 29
12.11 Strength of materials and parts . 29
12.11.1 General . 29
12.11.2 Mechanical impact . 29
12.11.3 Environmental conditions . 30
12.11.4 Properties of insulating materials . 30
13 Overload and short-circuit protection . 31
14 Electromagnetic compatibility (EMC) . 31
14.1 General . 31
14.2 EMC of the BSS . 32
14.3 Functional safety related to EMC . 32
15 Emergency switching or disconnect (optional) . 32
16 Marking and instructions . 32
16.1 Installation manual of battery swap station . 32
16.2 User manual for battery swap station . 33
16.3 Marking of battery swap station. 33
16.3.1 General . 33
16.3.2 Marking of equipment . 33
16.4 Legibility . 33
16.5 Signals and warning devices . 34
Annex A (informative) Interface of system A for type B BSS . 35
A.1 General . 35
A.2 Interface circuit . 35
A.2.1 Interface circuit diagram . 35
A.2.2 Control pilot circuit . 36
A.3 State transition of charging control process . 37
Annex B (informative) Interface of system B for type
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