FprEN IEC 62840-2:2025

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.

Batteriewechselsysteme für Elektrofahrzeuge - Teil 2: Sicherheitsanforderungen

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.

Sistem menjave baterij v električnih vozilih - 2. del: Varnostne zahteve

General Information

• Status: Not Published
• Publication Date: 03-Aug-2025
• ICS: 43.120 - Electric road vehicles
• Technical Committee: CLC/TC 69X - Electrical systems for electric road vehicles
• Drafting Committee: IEC/TC 69 - IEC_TC_69
• Current Stage: 5060 - Voting results sent to TC, SR - Formal Approval
• Start Date: 02-May-2025
• Completion Date: 02-May-2025
• Directive: 2014/35/EU - Directive 2014/35/EU of the European Parliament and of the Council of 26 February 2014 on the harmonisation of the laws of the Member States relating to the making available on the market of electrical equipment designed for use within certain voltage limits
• Directive: 2014/94/EU - Directive 2014/94/EU of The European Parliament and of The Council of 22 October 2014 on the deployment of alternative fuels infrastructure
• Directive: 2023/1804 - Regulation (EU) 2023/1804 of the European Parliament and of the Council of 13 September 2023 on the deployment of alternative fuels infrastructure, and repealing Directive 2014/94/EU
• Directive: 2023/1804-1 - Regulation (EU) 2023/1804 of the European Parliament and of the Council of 13 September 2023 on the deployment of alternative fuels infrastructure, and repealing Directive 2014/94/EU
• Directive: 2023/1804-2 - Regulation (EU) 2023/1804 of the European Parliament and of the Council of 13 September 2023 on the deployment of alternative fuels infrastructure, and repealing Directive 2014/94/EU
• Mandate: M/511 - Mandate to CEN, CENELEC and ETSI relating to harmonised standards in the field of the Low Voltage Directive
• Mandate: M/533 - [C(2015)1330] Standardisation request addressed to CEN, CENELEC and ETSI in support of the implementation of the Directive 2014/94/EU on the deployment of alternative fuels infrastructure
• Mandate: M/581 - Standardisation Request as regards communication exchange, electricity, and hydrogen supply for road, maritime transport and inland navigation in support of Directive 2014/94/EU and its planned revision under the ‘Fit for 55’package
• Mandate: M/591 - Standardisation request to the European Committee for Standardisation and the European Committee for Electrotechnical Standardisation as regards railway products in support of Directive (EU) 2016/797
• Ref Project: kSIST FprEN IEC 62840-2:2025 - Electric vehicle battery swap system - Part 2: Safety requirements

Relations

• Revises: EN IEC 62840-2:2019 - Electric vehicle battery swap system - Part 2: Safety requirements
• Effective Date: 31-Aug-2021

Standards Content (Sample)

SLOVENSKI STANDARD
oSIST prEN IEC 62840-2:2024
01-julij-2024
Sistem menjave baterij v električnih vozilih - 2. del: Varnostne zahteve
Electric vehicle battery swap system - Part 2: Safety requirements
Batteriewechselsysteme für Elektrofahrzeuge - Teil 2: Sicherheitsanforderungen
Système d'échange de batterie pour véhicule électrique - Partie 2: Exigences de sécurité
Ta slovenski standard je istoveten z: prEN IEC 62840-2:2024
ICS:
43.120 Električna cestna vozila Electric road vehicles
oSIST prEN IEC 62840-2:2024 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

oSIST prEN IEC 62840-2:2024
oSIST prEN IEC 62840-2:2024
69/955/CDV
COMMITTEE DRAFT FOR VOTE (CDV)
PROJECT NUMBER:
IEC 62840-2 ED2
DATE OF CIRCULATION: CLOSING DATE FOR VOTING:
2024-05-17 2024-08-09
SUPERSEDES DOCUMENTS:
69/910/CD, 69/954/CC
IEC TC 69 : ELECTRICAL POWER/ENERGY TRANSFER SYSTEMS FOR ELECTRICALLY PROPELLED ROAD VEHICLES AND INDUSTRIAL
TRUCKS
SECRETARIAT: SECRETARY:
Belgium Mr Peter Van den Bossche
OF INTEREST TO THE FOLLOWING COMMITTEES: PROPOSED HORIZONTAL STANDARD:

Other TC/SCs are requested to indicate their interest, if any, in
this CDV to the secretary.
FUNCTIONS CONCERNED:
EMC ENVIRONMENT QUALITY ASSURANCE SAFETY
SUBMITTED FOR CENELEC PARALLEL VOTING NOT SUBMITTED FOR CENELEC PARALLEL VOTING
Attention IEC-CENELEC parallel voting
The attention of IEC National Committees, members of
CENELEC, is drawn to the fact that this Committee Draft
for Vote (CDV) is submitted for parallel voting.
The CENELEC members are invited to vote through the
CENELEC online voting system.
This document is still under study and subject to change. It should not be used for reference purposes.
Recipients of this document are invited to submit, with their comments, notification of any relevant patent rights of which
they are aware and to provide supporting documentation.
Recipients of this document are invited to submit, with their comments, notification of any relevant “In Some Countries”
clauses to be included should this proposal proceed. Recipients are reminded that the CDV stage is the final stage for
submitting ISC clauses. (SEE AC/22/2007 OR NEW GUIDANCE DOC).

TITLE:
Electric vehicle battery swap system - Part 2: Safety requirements

PROPOSED STABILITY DATE: 2026
NOTE FROM TC/SC OFFICERS:
electronic file, to make a copy and to print out the content for the sole purpose of preparing National Committee positions.
You may not copy or "mirror" the file or printed version of the document, or any part of it, for any other purpose without
permission in writing from IEC.

oSIST prEN IEC 62840-2:2024
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1 CONTENTS
2 FOREWORD . 5
3 INTRODUCTION . 7
4 1 Scope . 8
5 2 Normative references . 8
6 3 Terms and definitions . 10
7 4 Abbreviations . 11
8 5 General requirements . 11
9 6 Classification . 12
10 7 Safety requirements of systems . 12
11 7.1 General . 12
12 7.2 Lane system . 12
13 7.2.1 Vehicle lane . 12
14 7.2.2 Measures in case of emergency . 12
15 7.3 Battery handling system . 12
16 7.3.1 Interlock protection guarding . 12
17 7.3.2 Interlock with the lane . 13
18 7.3.3 Battery handling process . 13
19 7.3.4 Measures in case of emergency . 14
20 7.4 Storage system . 14
21 7.4.1 Battery storage . 14
22 7.4.2 Measures in case of emergency . 14
23 7.5 Charging system . 15
24 7.5.1 SBS/RBS charger . 15
25 7.5.2 Charger connection . 15
26 7.5.3 Charging rack . 15
27 7.5.4 Communication and monitoring . 15
28 7.6 Swappable battery system/Removable battery system . 16
29 7.7 Supervisory and control system . 17
30 7.8 Supporting systems . 17
31 7.8.1 Battery maintenance system . 17
32 7.8.2 SBS/RBS logistic system . 18
33 7.9 Power supply system . 18
34 7.10 Interfaces . 18
35 8 Communications . 18
36 8.1 Data security. 18
37 8.2 Transmission of safety related messages . 18
38 8.3 Telecommunication network . 18
39 9 Protection against electric shock . 18
40 9.1 General requirements . 18
41 9.2 Protection against direct contact . 19
42 9.2.1 IP degrees for the shock prevention. 19
43 9.2.2 IP degrees for coupler . 19
44 9.2.3 Bidirectional energy transfer . 19
45 9.3 Stored energy – discharge of capacitors . 19
46 9.4 Fault protection . 20

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47 9.5 Protective conductor . 20
48 9.6 Supplementary measures . 20
49 9.6.1 Additional protection . 20
50 9.6.2 Manual/automatic reset . 20
51 9.6.3 Protection of persons against electric shock . 21
52 10 Specific requirements for accessories . 21
53 11 Cable assembly requirements . 21
54 12 BSS constructional requirements and tests . 21
55 12.1 General . 21
56 12.2 Characteristics of mechanical switching devices . 21
57 12.2.1 Switch and switch-disconnector . 21
58 12.2.2 Contactor . 21
59 12.2.3 Circuit-breaker . 22
60 12.2.4 Relays . 22
61 12.2.5 Metering . 22
62 12.2.6 Switch-on peak current/Inrush current . 22
63 12.3 Clearances and creepage distances . 22
64 12.4 IP degrees for the penetration . 22
65 12.5 Insulation resistance . 23
66 12.6 Touch current . 23
67 12.7 Dielectric withstand voltage . 23
68 12.8 Temperature rise . 24
69 12.9 Damp heat functional test . 24
70 12.10 Minimum temperature functional test . 24
71 12.11 Strength of materials and parts . 25
72 12.11.1 General . 25
73 12.11.2 Mechanical impact . 25
74 12.11.3 Environmental conditions . 25
75 12.11.4 Properties of insulating materials . 25
76 13 Overload and short circuit protection . 26
77 14 EMC . 26
78 14.1 General . 26
79 14.2 EMC of the BSS . 27
80 14.3 Functional safety related to EMC . 27
81 15 Emergency switching or disconnect(optional) . 27
82 16 Marking and instructions . 27
83 16.1 Installation manual of battery swap station . 27
84 16.2 User manual for battery swap station . 27
85 16.3 Marking of battery swap station . 28
86 16.3.1 General . 28
87 16.3.2 Marking of equipment. 28
88 16.4 Legibility . 28
89 16.5 Signals and warning devices . 28
90 Annex A (informative) Interface of system A for battery swap station type B . 30
91 A.1 General . 30
92 A.2 Interface circuit . 30
93 A.2.1 Interface circuit diagram . 30
94 A.2.2 Control pilot circuit . 31

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95 A.3 State transition of charging control process. 32
96 Annex B (informative) Type B BSS - System B .
...