EN IEC 62840-2:2019

Electric vehicle battery swap system - Part 2: Safety requirements

IEC 62840-2:2016 provides the safety requirements for a battery swap system, for the purposes of swapping swappable battery system (SBS) 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 d.c, in accordance with IEC 60038. This standard also applies to battery swap systems supplied from on-site storage systems (e.g. buffer batteries). This publication is to be read in conjunction with IEC 62840-1:2016.

Batteriewechselsysteme für Elektrofahrzeuge - Teil 2: Sicherheitsanforderungen

Système d'échange de batterie de véhicule électrique - Partie 2: Exigences de sécurité

L'IEC 62840-2:2016 spécifie les exigences de sécurité relatives à un système d'échange de batterie, pour remplacer le système de batterie échangeable (SBS) 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. La présente norme s'applique également aux systèmes d'échange de batterie alimentés par des systèmes de stockage sur site (par exemple, des batteries tampons). Cette publication doit être lue conjointement avec la IEC 62840-1:2016

Sistem menjave baterij električnih vozil - 2. del: Varnostne zahteve

Ta del standarda IEC 62840 podaja varnostne zahteve za sistem menjave baterij za namene menjave zamenljivih baterijskih sistemov (SBS) pri električnih vozilih. Sistem menjave baterij je predviden za priključitev na napajalno omrežje. Zmogljivost električnega napajalnika je največ 1000 V pri izmeničnem toku ali največ 1500 V pri enosmernem toku v skladu s standardom IEC 60038.
Ta standard se uporablja tudi za sisteme menjave baterij, dobavljene iz sistemov za shranjevanje na mestu uporabe (npr. nadomestne baterije).
Vidiki, zajeti v tem standardu:
• varnostne zahteve sistema menjave baterij in/ali njegovih sistemov;
• varnostne zahteve za komunikacijo;
• elektromagnetna združljivost (EMC);
• oznake in navodila;
• zaščita pred električnim udarom in drugimi nevarnostmi.
Ta standard se uporablja za sisteme menjave baterij za električna vozila, opremljena z vsaj enim sistemom SBS.
OPOMBA: Obravnavani so sistemi menjave baterij za lahka električna vozila v skladu s skupino standardov IEC 61851-3.
Ta standard se ne uporablja za:
• vidike v povezavi z vzdrževanjem in servisiranjem postaje za menjavo baterij (BSS);
• trolejbuse, železniška vozila in vozila, ki so namenjena predvsem za uporabo zunaj cestišč;
• vzdrževanje in servisiranje električnih vozil.

General Information

• Status: Published
• Publication Date: 31-Jan-2019
• Withdrawal Date: 31-Jan-2022
• 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: 6060 - Document made available - Publishing
• Start Date: 01-Feb-2019
• Completion Date: 01-Feb-2019
• 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
• 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
• Ref Project: SIST EN IEC 62840-2:2019 - Electric vehicle battery swap system - Part 2: Safety requirements

Relations

• Replaced By: EN IEC 62840-2:2025 - Electric vehicle battery swap system - Part 2: Safety requirements
• Effective Date: 31-Aug-2021

Overview

EN IEC 62840-2:2019 - "Electric vehicle battery swap system - Part 2: Safety requirements" - specifies safety requirements for battery swap systems used to swap swappable battery systems (SBS) of electric vehicles. It covers systems intended to be connected to the supply network (up to 1 000 V AC or 1 500 V DC, per IEC 60038) and also applies to stations supplied from on‑site storage (for example, buffer batteries). This standard is intended to be read together with IEC/EN 62840-1:2016 (general guidance).

Key topics and technical requirements

The standard addresses system-level and equipment safety across the battery swap lifecycle. Key technical topics include:

• System safety and architecture
  • Lane systems and vehicle lanes, emergency measures and interlocks
  • Battery handling systems: mechanical handling, interlock protection, safe battery transfer
  • Storage systems for swappable batteries, including emergency procedures
• Power and charging
  • SBS charger requirements, charger connection, charging racks, and charging safety
  • Power supply considerations for grid-connected and on-site stored energy
• Protection against electric shock
  • Requirements for direct and indirect contact protection, IP ratings for enclosures and couplers, discharge of stored energy (capacitors), protective conductors and fault protection
• Control, communications and monitoring
  • Supervisory/control systems, communication of safety-related messages, and data security
• Construction and component requirements
  • Clearances and creepage distances, mechanical strength, material properties, selection of circuit-breakers, contactors, relays and metering
• Electromagnetic compatibility (EMC) and functional safety
  • EMC immunity/compatibility for safety-related systems and references to functional safety practices

Practical applications and users

EN IEC 62840-2:2019 is used by:

• EV charging station designers and system integrators building battery swap stations
• Electric vehicle and battery manufacturers defining SBS interfaces and safety features
• Operators and owners of battery swap stations for safe installation, commissioning and operation
• Safety engineers and risk assessors performing hazard analyses and compliance checks
• Test labs and certification bodies verifying conformity with electrical, mechanical and EMC safety requirements
• Regulators and infrastructure planners creating code and permitting guidance for battery swap deployment

Practical uses include design specifications, creating technical requirements for procurement, establishing operational procedures (emergency stop, isolation, interlocks), and developing maintenance and testing programs.

Related standards

This standard references and is intended to be used alongside other standards such as IEC 62840-1, IEC 60038, IEC 61851-23, IEC 60364 series (low-voltage installations), IEC 60529 (IP codes), IEC 60664-1 (insulation coordination), IEC 61508 (functional safety), and EMC standards - all important for complete safety compliance of battery swap systems.

Keywords: EN IEC 62840-2:2019, battery swap system, safety requirements, electric vehicle, swappable battery system, SBS, charging system, protection against electric shock, EMC.

Standards Content (Sample)

SLOVENSKI STANDARD
01-maj-2019
6LVWHPPHQMDYHEDWHULMHOHNWULþQLKYR]LOGHO9DUQRVWQH]DKWHYH
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: EN IEC 62840-2:2019
ICS:
43.120 (OHNWULþQDFHVWQDYR]LOD Electric road vehicles
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

EUROPEAN STANDARD EN IEC 62840-2

NORME EUROPÉENNE
EUROPÄISCHE NORM
February 2019
ICS 43.120
English Version
Electric vehicle battery swap system - Part 2: Safety
requirements
(IEC 62840-2:2016)
Système d'échange de batterie de véhicule électrique - Batteriewechselsysteme für Elektrofahrzeuge - Teil 2:
Partie 2: Exigences de sécurité Sicherheitsanforderungen
(IEC 62840-2:2016) (IEC 62840-2:2016)
This European Standard was approved by CENELEC on 2016-11-08. CENELEC 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.
Up-to-date lists and bibliographical references concerning such national standards may be obtained on application to the CEN-CENELEC
Management Centre or to any CENELEC member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CENELEC member into its own language and notified to the CEN-CENELEC Management Centre has the
same status as the official versions.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Bulgaria, Croatia, Cyprus, the Czech Republic,
Denmark, Estonia, Finland, Former Yugoslav Republic of Macedonia, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia,
Lithuania, Luxembourg, Malta, the Netherlands, Norway, Poland, Portugal, Romania, Serbia, Slovakia, Slovenia, Spain, Sweden,
Switzerland, Turkey and the United Kingdom.

European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung
CEN-CENELEC Management Centre: Rue de la Science 23, B-1040 Brussels
© 2019 CENELEC All rights of exploitation in any form and by any means reserved worldwide for CENELEC Members.
Ref. No. EN IEC 62840-2:2019 E

European foreword
The text of document 69/420/FDIS, future edition 1 of IEC 62840-2, prepared by IEC/TC 69 "Electric
road vehicles and electric industrial trucks" was submitted to the IEC-CENELEC parallel vote and
approved by CENELEC as EN IEC 62840-2:2019.
The following dates are fixed:
(dop) 2019-08-01
• latest date by which the document has to be implemented at
national level by publication of an identical national
standard or by endorsement
(dow) 2022-02-01
• latest date by which the national standards conflicting with
the document have to be withdrawn
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. CENELEC shall not be held responsible for identifying any or all such patent rights.
Endorsement notice
The text of the International Standard IEC 62840-2:2016 was approved by CENELEC as a European
Standard without any modification.
In the official version, for Bibliography, the following notes have to be added for the standards indicated:
IEC 60947-5-1 NOTE Harmonized as EN 60947-5-1.
IEC 61000 series NOTE Harmonized in EN 61000 series.
IEC 61851-1 NOTE Harmonized as EN 61851-1.
IEC 61851-21-2 NOTE Harmonized as EN 61851-21-2 .
IEC 61851-3 series NOTE Harmonized in CLC/TS 61851-3 series .
ISO 4413 NOTE Harmonized as EN ISO 4413
ISO 4414 NOTE Harmonized as EN ISO 4414

Under preparation. Stage at time of publication: CLC/prTS 61851 series.
EN IEC 62840 2:2019 (E)
Annex ZA
(normative)
Normative references to international publications
with their corresponding European publications
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.
NOTE 1 When an International Publication has been modified by common modifications, indicated by (mod),
the relevant EN/HD applies.
NOTE 2 Up-to-date information on the latest versions of the European Standards listed in this annex is
available here: www.cenelec.eu.

Publication Year Title EN/HD Year
IEC 60038 -  IEC standard voltages EN 60038 -
IEC 60112 -  Method for the determination of the EN 60112 -
proof and the comparative tracking
indices of solid insulating materials
IEC 60204-1 -  Safety of machinery - Electrical EN 60204-1 -
equipment of machines -
Part 1: General requirements
IEC 60364 series Low-voltage electrical installations HD 384 / series
HD 60364
IEC 60364-4-41 (mod) 2005 Low-voltage electrical installations - HD 60364-4-41 2007
Part 4-41: Protection for safety -
+ A11 2017
- -
Protection against electric shock
IEC 60364-5-54 -  Low-voltage electrical installations - HD 60364-5-54 -
Part 5-54: Selection and erection of
electrical equipment - Earthing
arrangements and protective conductors
IEC 60364-7-722 -  Low-voltage electrical installations - HD 60364-7-722 -
Part 7-722: Requirements for special
installations or locations - Supplies for
electric vehicles
IEC/TS(TR) 60479 series Effects of current on human beings and - -
livestock
IEC 60529 -  Degrees of protection provided by EN 60529 -
enclosures (IP Code)
IEC 60664-1 2007 Insulation coordination for equipment EN 60664-1 2007
within low-voltage systems -
Part 1: Principles, requirements and
tests
Publication Year Title EN/HD Year
IEC 60695-2-11 -  Fire hazard testing - EN 60695-2-11 -
Part 2-11: Glowing/hot-wire based test
methods - Glow-wire flammability test
method for end-products (GWEPT)
IEC 60695-10-2 -  Fire hazard testing - EN 60695-10-2 -
Part 10-2: Abnormal heat - Ball pressure
test method
IEC/TR 60755 -  General requirements for residual - -
current operated protective devices
IEC 60898-1 -  Electrical accessories - Circuit-breakers EN 60898-1 -
for overcurrent protection for household
and similar installations -
Part 1: Circuit-breakers for a.c.
operation
IEC 60947-2 -  Low voltage switchgear and EN 60947-2 -
controlgear -
Part 2: Circuit-breakers
IEC 60947-3 -  Low-voltage switchgear and EN 60947-3 -
controlgear -
Part 3: Switches, disconnectors, switch-
disconnectors and fuse-combination
units
IEC 60947-4-1 -  Low-voltage switchgear and EN 60947-4-1 -
controlgear -
Part 4-1: Contactors and motor-starters -
Electromechanical contactors and
motor-starters
IEC 60950-1 (mod) 2005 Information technology equipment - EN 60950-1 2006
Safety -
- -  + A11 2009
Part 1: General requirements
+ A1 (mod) 2009 + A1 2010
- -  + A12 2011
- -  + AC 2011
+ A2 (mod) 2013 + A2 2013
IEC 61000-6-7 -  Electromagnetic compatibility (EMC) - EN 61000-6-7 -
Part 6-7: Generic standards - Immunity
requirements for equipment intended to
perform functions in a safety-related
system (functional safety) in industrial
locations
IEC 61008 series Residual current operated circuit- EN 61008 series
breakers without integral overcurrent
protection for household and similar
uses (RCCB's)
IEC 61008-1 -  Residual current operated circuit- EN 61008-1 -
breakers without integral overcurrent
protection for household and similar
uses (RCCB's) -
Part 1: General rules
EN IEC 62840 2:2019 (E)
Publication Year Title EN/HD Year
IEC 61009 series Residual current operated circuit- EN 61009 series
breakers with integral overcurrent
protection for household and similar
uses (RCBOs)
IEC 61009-1 -  Residual current operated circuit- EN 61009-1 -
breakers with integral overcurrent
protection for household and similar
uses (RCBOs) -
Part 1: General rules
IEC 61140 -  Protection against electric shock - EN 61140 -
Common aspects for installation and
equipment
IEC 61439-1 2011 Low-voltage switchgear and controlgear EN 61439-1 2011
assemblies -
Part 1: General rules
IEC 61508-1 -  Functional safety of EN 61508-1 -
electrical/electronic/programmable
electronic safety-related systems -
Part 1: General requirements
IEC 61511-1 -  Functional safety - Safety instrumented EN 61511-1 -
systems for the process industry sector -
Part 1: Framework, definitions, system,
hardware and application programming
requirements
IEC 61784-3 -  Industrial communication networks - EN 61784-3 -
Profiles -
Part 3: Functional safety fieldbuses -
General rules and profile definitions
IEC 61810-1 -  Electromechanical elementary relays - EN 61810-1 -
Part 1: General and safety requirements
IEC 61851-23 2014 Electric vehicle conductive charging EN 61851-23 2014
system -
Part 23: D.C. electric vehicle charging
station
IEC 62052-11 -  Electricity metering equipment (AC) - EN 62052-11 -
General requirements, tests and test
conditions -
Part 11: Metering equipment
IEC 62262 -  Degrees of protection provided by EN 62262 -
enclosures for electrical equipment
against external mechanical impacts (IK
code)
IEC 62423 -  Type F and type B residual current EN 62423 -
operated circuit-breakers with and
without integral overcurrent protection
for household and similar uses
IEC 62840-1 2016 Electric vehicle battery swap system - - -
Part 1: General and guidance
ISO 2972 -  Numerical control of machines; Symbols - -
ISO 7000 -  Graphical symbols for use on - -
equipment - Registered symbols
Publication Year Title EN/HD Year
ISO 10218-1 -  Robots and robotic devices - Safety EN ISO 10218-1 -
requirements for industrial robots -
Part 1: Robots
ISO 10218-2 -  Robots and robotic devices - Safety EN ISO 10218-2 -
requirements for industrial robots -
Part 2: Robot systems and integration
ISO 12405-1 -  Electrically propelled road vehicles - - -
Test specification for lithium-ion traction
battery packs and systems -
Part 1: High-power applications
ISO 13849-1 -  Safety of machinery - Safety-related EN ISO 13849-1 -
parts of control systems -
Part 1: General principles for design
ISO 14119 -  Safety of machinery - Interlocking EN ISO 14119 -
devices associated with guards -
Principles for design and selection

IEC 62840-2 ®
Edition 1.0 2016-10
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Electric vehicle battery swap system –

Part 2: Safety requirements
Système d'échange de batterie de véhicule électrique –

Partie 2: Exigences de sécurité

INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 43.120 ISBN 978-2-8322-3632-1

– 2 – IEC 62840-2:2016 © IEC 2016
CONTENTS
FOREWORD . 4
INTRODUCTION . 6
1 Scope . 7
2 Normative references. 7
3 Terms and definitions . 9
4 General . 11
5 Safety requirements of systems . 11
5.1 General . 11
5.2 Lane system . 12
5.2.1 Vehicle lane . 12
5.2.2 Measures in case of emergency . 12
5.3 Battery handling system . 12
5.3.1 Interlock protection guarding . 12
5.3.2 Interlock with the lane . 12
5.3.3 Battery handling process . 12
5.3.4 Measures in case of emergency . 13
5.4 Storage system . 13
5.4.1 Battery storage . 13
5.4.2 Measures in case of emergency . 14
5.5 Charging system . 14
5.5.1 SBS charger . 14
5.5.2 Charger connection . 14
5.5.3 Charging rack . 15
5.5.4 Communication and monitoring . 15
5.6 Swappable battery system . 15
5.7 Supervisory and control system . 15
5.8 Supporting systems . 16
5.8.1 Battery maintenance system . 16
5.8.2 SBS logistic system . 16
5.9 Power supply system . 16
6 Communication . 17
6.1 Data security . 17
6.2 Transmission of safety related messages . 17
7 Protection against electric shock . 17
7.1 General requirements . 17
7.2 Protection against direct contact . 17
7.2.1 IP degrees for the enclosures . 17
7.2.2 IP degrees for coupler . 18
7.2.3 Bidirectional energy transfer . 18
7.3 Stored energy – discharge of capacitors . 18
7.4 Fault protection . 18
7.5 Protective conductor . 19
7.6 Supplementary measures . 19
7.6.1 Additional protection . 19
7.6.2 Manual/automatic reset . 19

IEC 62840-2:2016 © IEC 2016 – 3 –
7.6.3 Protection of persons against electric shock . 20
7.7 Telecommunication network . 20
8 Equipment constructional requirements . 20
8.1 General . 20
8.2 Characteristics of mechanical switching devices . 20
8.2.1 Switch and switch-disconnector . 20
8.2.2 Contactor . 20
8.2.3 Circuit-breaker . 21
8.2.4 Relays . 21
8.2.5 Metering . 21
8.3 Clearances and creepage distances . 21
8.4 Strength of materials and parts . 21
8.4.1 General . 21
8.4.2 Mechanical impact . 21
8.4.3 Environmental conditions . 21
8.4.4 Properties of insulating materials . 22
9 Electromagnetic compatibility (EMC) . 23
9.1 General . 23
9.2 EMC of the BSS . 23
9.3 Functional safety related to EMC . 23
10 Marking and instructions . 23
10.1 General . 23
10.2 Marking of equipment . 23
10.3 Legibility . 24
10.4 Signals and warning devices . 24
Bibliography . 26

– 4 – IEC 62840-2:2016 © IEC 2016
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
ELECTRIC VEHICLE BATTERY SWAP SYSTEM –

Part 2: Safety requirements
FOREWORD
1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, IEC publishes International Standards, Technical Specifications,
Technical Reports, Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC
Publication(s)”). Their preparation is entrusted to technical committees; any IEC National Committee interested
in the subject dealt with may participate in this preparatory work. International, governmental and non-
governmental organizations liaising with the IEC also participate in this preparation. IEC collaborates closely
with the International Organization for Standardization (ISO) in accordance with conditions determined by
agreement between the two organizations.
2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international
consensus of opinion on the relevant subjects since each technical committee has representation from all
interested IEC National Committees.
3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC
Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any
misinterpretation by any end user.
4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications
transparently to the maximum extent possible in their national and regional publications. Any divergence
between any IEC Publication and the corresponding national or regional publication shall be clearly indicated in
the latter.
5) IEC itself does not provide any attestation of conformity. Independent certification bodies provide conformity
assessment services and, in some areas, access to IEC marks of conformity. IEC is not responsible for any
services carried out by independent certification bodies.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
members of its technical committees and IEC National Committees for any personal injury, property damage or
other damage of any nature whatsoever, whether direct or indirect, or for costs (including legal fees) and
expenses arising out of the publication, use of, or reliance upon, this IEC Publication or any other IEC
Publications.
8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is
indispensable for the correct application of this publication.
9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of
patent rights. IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 62840-2 has been prepared by IEC technical committee 69:
Electric road vehicles and electric industrial trucks.
The text of this standard is based on the following documents:
FDIS Report on voting
69/420/FDIS 69/433/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 2.
This standard is to be read in conjunction with IEC 62840-1:2016.

IEC 62840-2:2016 © IEC 2016 – 5 –
in this document, the following print types are used:
– requirements: in roman type;
– test specifications: in italic type;
– notes: in small roman type.
A list of all parts in the IEC 62840 series, published under the general title Electric vehicle
battery swap system, can be found on the IEC website.
The following differing practices of a less permanent nature exist in the countries indicated
below
– 7.6.1: RCDs of type AC may be used (Japan).
– 7.6.1: a device which measures leakage current over a range of frequencies and trips at
pre-defined levels of leakage current, based upon the frequency, is required (United
States).
– 10.4: three-part cautionary statements are required (United States).
The committee has decided that the contents of this publication will remain unchanged until
the stability date indicated on the IEC website under "http://webstore.iec.ch" in the data
related to the specific publication. At this date, the publication will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
– 6 – IEC 62840-2:2016 © IEC 2016
INTRODUCTION
The purpose of the battery swap system is to provide energy partly or in total to electric
vehicles (EV) through fast replacement of their swappable battery systems (SBS). While
charging, the EV typically takes a relatively long time, whereas the battery swap process
takes only a few minutes to complete. Thus it will reduce the range anxiety and will facilitate
travel for longer distances.
As there is a possibility to charge the batteries after their removal from the vehicle in various
ways, the impact of this process on the critical infrastructure of the electrical grid can be
minimized.
Battery swap stations mainly include one or more of the following functions:
• swap of EV swappable battery system (SBS);
• storage of EV SBS;
• charging and cooling of EV SBS;
• testing, maintenance and safety management of EV SBS.
This part of IEC 62840 serves as a generic approach for safety during the lifecycle of battery
swap systems and stations for electric vehicles.

IEC 62840-2:2016 © IEC 2016 – 7 –
ELECTRIC VEHICLE BATTERY SWAP SYSTEM –

Part 2: Safety requirements
1 Scope
This part of IEC 62840 provides the safety requirements for a battery swap system, for the
purposes of swapping swappable battery system (SBS) 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 d.c, in accordance with IEC 60038.
This standard also applies to battery swap systems supplied from on-site storage systems
(e.g. buffer batteries).
Aspects covered in this standard:
• safety requirements of the battery swap system and/or its systems;
• security requirements for communication;
• electromagnetic compatibility (EMC);
• signs and instructions;
• protection against electric shock and other hazards.
This standard is applicable to battery swap systems for EV equipped with one or more SBS.
NOTE Battery swap systems for light EVs according to the IEC 61851-3 series are under consideration.
This standard 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;
• maintenance and service of EVs.
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.
IEC 60038, IEC standard voltages
IEC 60112, Method for the determination of the proof and the comparative tracking indices of
solid insulating materials
IEC 60204-1, Safety of machinery – Electrical equipment of machines – General requirements
IEC 60364 (all parts), Low-voltage electrical installations
_____________
Under consideration.
– 8 – IEC 62840-2:2016 © IEC 2016
IEC 60364-4-41:2005, Low-voltage electrical installations – Part 4-41: Protection for safety –
Protection against electric shock
IEC 60364-5-54, Low-voltage electrical installations – Part 5-54: Selection and erection of
electrical equipment – Earthing arrangements and protective conductors
IEC 60364-7-722, Low-voltage electrical installations – Part 7-722: Requirements for special
installations or locations – Supply of electric vehicle
IEC 60479 (all parts), Effects of current on human beings and livestock
IEC 60529, Degrees of protection provided by enclosures (IP Code)
IEC 60664-1:2007, Insulation coordination for equipment within low-voltage systems – Part 1:
Principles, requirements and tests
IEC 60695-2-11, Fire hazard testing – Part 2-11: Glowing/hot-wire based test methods –
Glow-wire flammability test method for end-products (GWEPT)
IEC 60695-10-2, Fire hazard testing – Part 10-2: Abnormal heat – Ball pressure test method
IEC TR 60755, General requirements for residual current operated protective devices
IEC 60898-1, Electrical accessories – Circuit-breakers for overcurrent protection for
household and similar installations – Part 1: Circuit-breakers for a.c. operation
IEC 60947-2, Low-voltage switchgear and control gear – Part 2: Circuit-breakers
IEC 60947-3, Low-voltage switchgear and controlgear – Part 3: Switches, disconnectors,
switch-disconnectors and fuse-combination units
IEC 60947-4-1, Low-voltage switchgear and controlgear – Part 4-1: Contactors and motor-
starters – Electromechanical contactors and motor-starters
IEC 60950-1:2005, Information technology equipment – Safety – Part 1: General requirements
IEC 60950-1:2005/AMD1:2009
IEC 60950-1:2005/AMD2:2013
IEC 61000-6-7, Electromagnetic compatibility (EMC) – Part 6-7: Generic standards –
Immunity requirements equipment intended to perform functions in a safety-related system
(functional safety) in industrial environments
IEC 61008 (all parts), Residual current operated circuit-breakers without integral overcurrent
protection for household and similar uses (RCCBs)
IEC 61008-1, Residual current operated circuit-breakers without integral overcurrent
protection for household and similar uses (RCCBs) – Part 1: General rules
IEC 61009 (all parts), Residual current operated circuit-breakers with integral overcurrent
protection for household and similar uses (RCBOs)
IEC 61009-1, Residual current operated circuit-breakers with integral overcurrent protection
for household and similar uses (RCBOs) – Part 1: General rules
IEC 61140, Protection against electric shock – Common aspects for installation and
equipment
IEC 62840-2:2016 © IEC 2016 – 9 –
IEC 61439-1:2011, Low-voltage switchgear and controlgear assemblies – Part 1: General
rules
IEC 61508-1, Functional safety of electrical/electronic/programmable electronic safety-related
systems – Part 1: General requirements
IEC 61511-1, Functional safety – Safety instrumented systems for the process industry sector
– Part 1: Framework, definitions, system, hardware and application programming
requirements
IEC 61784-3, Industrial communication networks – Profiles – Part 3: Functional safety
fieldbuses – General rules and profile definitions
IEC 61810-1, Electromechanical elementary relays – Part 1: General and safety requirements
IEC 61851-23:2014, Electric vehicle conductive charging system – Part 23: DC electric
vehicle charging station
IEC 62052-11, Electricity metering equipment (AC) – General requirements, tests and test
conditions – Part 11: Metering equipment
IEC 62262, Degrees of protection provided by enclosures for electrical equipment against
external mechanical impacts (IK code)
IEC 62423, Type F and type B residual current operated circuit-breakers with and without
integral overcurrent protection for household and similar uses
IEC 62840-1:2016, Electric vehicle battery swap system – Part 1: General and guidance
ISO 2972, Numerical control of machines – Symbols
ISO 7000, Graphical symbols for use on equipment – Registered symbols
ISO 10218-1, Robots and robotic devices – Safety requirements for industrial robots – Part 1:
Robots
ISO 10218-2, Robots and robotic devices – Safety requirements for industrial robots – Part 2:
Robot systems and integration
ISO 12405-1, Electrically propelled road vehicles – Test specification for lithium-ion traction
battery packs and systems – Part 1: High-power applications
ISO 13849-1, Safety of machinery –Safety-related parts of control systems – Part 1: General
principles for design
ISO 14119, Safety of machinery – Interlocking devices associated with guards – Principles for
design and selection
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 62840-1 and the
following apply.
– 10 – IEC 62840-2:2016 © IEC 2016
3.1
hazard
potential source of injury or death
3.2
operator
trained personnel who installs, operates, adjusts, maintains, cleans, repairs or works in the
battery swap station premises
3.3
direct contact
electric contact of persons or animals with live parts
[SOURCE: IEC 60050-195:1998, 195-06-03]
3.4
indirect contact
electric contact of persons or animals with exposed-conductive-parts which have become live
under fault conditions
[SOURCE: IEC 60050-195:1998, 195-06-04]
3.5
live part
conductor or conductive part intended to be energized in normal operation, including a neutral
conductor, but by convention not a PEN conductor or PEM conductor or PEL conductor
[SOURCE: IEC 60050-195:1998, 195-02-19, modified — The note to entry has been deleted.]
3.6
risk
combination of the probability of occurrence of harm and the severity of that harm
Note 1 to entry: In French, the term “risque” also denotes the potential source of harm, in English “hazard” (see
903-01-02). [ISO/IEC Guide 51:1999, definition 3.2]
[SOURCE: IEC 60050-903:1998, 903-01-07]
3.7
real time
pertaining to the processing of data by a computer in connection with another process outside
the computer according to time requirements imposed by the outside process
[SOURCE: IEC 60050-714:1992, 714-21-03]
3.8
alternating current
AC
electric current that is a periodic function of time with a zero direct component or, by
extension, a negligible direct component
Note 1 to entry: This note only applies to the French language.
[SOURCE: IEC 60050-131:2002, 131-11-24, modified — The note to entry has been replaced
by another one.]
IEC 62840-2:2016 © IEC 2016 – 11 –
3.9
direct current
DC
electric current that is time-independent or, by extension, periodic current the direct
component of which is of primary importance
Note 1 to entry: This note only applies to th French language.
[SOURCE: IEC 60050-131:2002, 131-11-22, modified — The note to entry has been replaced
by another one.]
3.10
residual current device
RCD
a mechanical switching device designed to make, carry and break currents under normal
service conditions and to cause the opening of the contacts when the residual current attains
a given value under specified conditions
[SOURCE: IEC 60050-442:1998, 442-05-02, modified — The note to entry has been deleted.]
4 General
The battery swap system shall be rated for one, or a range of, standard nominal voltages
according to IEC 60038. The safe operation of a battery swap system will be achieved by
fulfilling the relevant requirements specified in this standard, and compliance is checked by
carrying out all relevant tests.
The battery swap system shall be so designed and constructed that in normal use its
performance is reliable and minimizes the risk of danger to the human individuals, equipment
and surroundings.
In general, this principle is achieved by fulfilling the relevant requirements specified by this
standard and IEC 62840-1, together with IEC 61851-21-2 . Compliance is checked by
carrying out the relevant tests.
Unless otherwise stated, tests may be conducted on separate samples at the discretion of the
manufacturer.
Unless otherwise specified, all other tests shall be carried out in the order of the clauses and
subclauses in this standard.
The electrical interface and communication interface characteristics of the battery swap
system will be specified in another part of the IEC 62840 series.
5 Safety requirements of systems
5.1 General
The battery swap system for electrical vehicles shall be in accordance with IEC 60204-1,
IEC 61511-1 and ISO 13849-1. Specific requirements are the subject of this standard.
_____________
Under consideration.
– 12 – IEC 62840-2:2016 © IEC 2016
5.2 Lane system
5.2.1 Vehicle lane
At the entrance to the lane, the EV information shall be identified and fed into the supervisor
and control system in order to use the right parameters and components for this vehicle.
The lane may include a cleaning station for the purposes of cleaning EV/battery parts before
the swap process starts. All lane system components shall be able to resist the effect of
automotive solvents and fluids.
Drivers and passengers may be allowed to stay on-board during the battery swap process.
The lane system shall be built in such a manner that humans and EVs are not at risk as a
result of movement of mechanical parts or as a result of open underground cavities.
5.2.2 Measures in case of emergency
During each phase of the battery swap process, the driver (if on board) and system operators
should have immediate access to emergency stop buttons to stop all automation motions in
case of emergency.
The lane shall be equipped with suitable escape routes and emergency exits allowing people
(if on board), including disabled persons, children and infants to evacuate from the lane area
in case of fire or other emergency.
All marking, routing and geometry of escape routes and exits should be done according to
local regulations.
5.3 Battery handling system
5.3.1 Interlock protection guarding
In automatic mode, a door or a sensor system shall be installed to prevent an unauthorized
person gaining access to the battery swap zone:
• if a door or access is opened, the system has to stop;
• the system can only operate if all accesses are closed;
• a door can be opened from outside only if the system stops;
• a door, if one exists, shall be able to open from inside in any case;
• a restart can only be performed if all accesses are closed and no person is inside the zone;
• ISO 14119 applies.
5.3.2 Interlock with the lane
The battery handling system shall only be enabled to operate when the vehicle is immobilized
and/or the vehicle powertrain is turned off.
During the battery handling process, the vehicle on the lane shall be immobilized by specific
measures (e.g. chocking and blocking the wheels, hand braking, turning off the powertrain).
5.3.3 Battery handling process
Battery handling systems shall have an emergency procedure when the SBS to be removed
from vehicle is suffering from a contact welding malfunction.
In automatic mode and semi-automatic mode, the battery handling system shall communicate
with the supervisory and control system. The operator should control the battery handling

IEC 62840-2:2016 © IEC 2016 – 13 –
system remotely through the human machine interface (HMI) or a remote control device which
allows the operator to be located a safe distance away from any moving parts.
The battery handling system shall be able to detect if the SBS has been unlocked successfully
before it moves the SBS out of the vehicle, and detect if the SBS is locked after it moves the
SBS into the vehicle.
An automatic battery handling system shall have the function of detecting presence of SBS in
the storage compartment to prevent an SBS being loaded into a compartment which is already
occupied by another SBS.
The battery handling system shall be designed in such a manner that deflections of structural
parts generated by SBS’s weight and/or acceleration of the system moving parts will not
cause SBS to fall down from their supports.
If the battery handling system is using a crane or lift type devices, all relevant safety
measures appearing in the regional machinery directive shall be respected.
Mechanical safety requirements for handling system shall be in accordance with ISO 10218-1
and ISO 10218-2 as far as applicable.
5.3.4 Measures in case of emergency
In the event of a grid power outage (loss of electrical power), the battery handling system
shall have a function that prevents the battery handling system from releasing unsafely.
The battery handling system of either automatic mode or semi-automatic mode shall have
emergency operation mode and manual operation mode.
An emergency stop device shall be provided, so that the operator can stop the battery
handling system immediately in case of emergency.
Detecting and warning devices or relevant protection measures are recommended in case of a
human or an animal having unexpected proximity to the system.
5.4 Storage system
5.4.1 Battery storage
The storage condition provided by the battery storage system shall comply with the specific
requirements of SBS. Structural elements carrying SBS in battery storage system shall be
rigid and precise enough to prevent a risk of a SBS falling down from a storage compartment.
Structural elements supporting SBS in the storage system shall be secured to the ground or to
the wall in such a manner that the structure shall not collapse under SBS weight or as the
result of impact or vibration, such as failure in undesired motion of automatic devices against
battery storage.
If SBS is not fully sealed, each SBS shall be separated by coverage from other SBS stored in
the same rack by at least IP4x.
If SBS is not fully sealed, each SBS shall be protected by coverage to avoid liquid drops from
other SBS stored in the same rack by at least IPx2.
The storage system shall be designed and constructed in accordance with local construction
regulations. The storage rack shall be equipped with locking device to prevent unintended
motion of SBS, and provide locking state information to the supervisor and control system.

– 14 – IEC 62840-2:2016 © IEC 2016
Safety critical parameters shall be monitored as long as the SBS is stored in the storage rack.
If there are no other local regulations or system requirements, the following parameters shall
be monitored:
• temperature of critical components;
• electrical malfunctions;
• locking state.
If any of these parameters are out of specific level, necessary actions shall be activated by
the supervisory and control system.
5.4.2 Measures in case of emergency
Rapid isolation or transfer of the battery in case of emergency shall be ensured, including the
following equipment:
• fire
...