IEC PAS 62840-3:2021

Electric vehicle battery swap system - Part 3: Particular safety and interoperability requirements for battery swap systems operating with removable RESS/battery systems

IEC PAS 62840-3:2021 applies to battery swap systems for removable RESS of electric road vehicle when connected to the supply network, with a rated supply voltage up to 480 V AC or up to 400 V DC, for battery systems with a rated voltage up to 120 V DC.
This document applies to battery swap systems for removable RESS/EV where the removable RESS/EV is stored for the purpose of transfer power between the battery swap station and removable RESS/EV.
Requirements for bidirectional energy transfer DC to AC are under consideration and are not part of this document.
This document applies to:
– battery swap systems supplied from on-site storage systems (for example buffer batteries etc;
– manual, mechanically assisted and automatic systems);
– battery swap systems intended to supply removable battery systems having communication allowing to identify the battery system characteristics;
– battery swap systems intended to be installed at an altitude of up to 2 000 m.
The aspects covered in this document include:
– requirements for power transfer between the battery systems;
– additional requirements for communication;
– the connection to supply network.
Additional requirements may apply to special locations.
This document does not apply to:
– safety requirements for mechanical equipment covered by ISO 10218 (all parts);
– locking compartments systems providing AC socket-outlets for the use of manufacturer specific voltage converter units and manufacturer specific battery systems;
– safety aspects related to maintenance;
– electrical devices and components which are covered by their specific product standards;
– trolley buses, rail vehicles;
– any on-board equipment which is covered by ISO;
– EMC requirements for on-board equipment while connected to the supply, which are covered by IEC 61851-21-1.
Requirements for battery swap systems using protective measures as covered by 410 of IEC 60364-4-41:2005 other than double or reinforced insulation are under consideration.

General Information

• Status: Published
• Publication Date: 26-Sep-2021
• ICS: 43.120 - Electric road vehicles
• Technical Committee: TC 69 - Electrical power/energy transfer systems for electrically propelled road vehicles and industrial trucks
• Current Stage: PPUB - Publication issued
• Completion Date: 27-Sep-2021

Standards Content (sample)

IEC PAS 62840-3
Edition 1.0 2021-09
PUBLICLY AVAILABLE
SPECIFICATION
PRE-STANDARD
Electric vehicle battery swap system –
Part 3: Particular safety and interoperability requirements for battery swap
systems operating with removable RESS/battery systems
IEC PAS 62840-3:2021-09(en)
---------------------- Page: 1 ----------------------
THIS PUBLICATION IS COPYRIGHT PROTECTED
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---------------------- Page: 2 ----------------------
IEC PAS 62840-3
Edition 1.0 2021-09
PUBLICLY AVAILABLE
SPECIFICATION
PRE-STANDARD
Electric vehicle battery swap system –
Part 3: Particular safety and interoperability requirements for battery swap
systems operating with removable RESS/battery systems
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 43.120 ISBN 978-2-8322-1031-6

Warning! Make sure that you obtained this publication from an authorized distributor.

® Registered trademark of the International Electrotechnical Commission
---------------------- Page: 3 ----------------------
– 2 – IEC PAS 62840-3:2021 © IEC 2021
CONTENTS

FOREWORD ........................................................................................................................... 4

INTRODUCTION ..................................................................................................................... 6

1 Scope .............................................................................................................................. 7

2 Normative references ...................................................................................................... 8

3 Terms and definitions ...................................................................................................... 9

4 Abbreviated terms ......................................................................................................... 12

5 General requirements .................................................................................................... 12

6 Classification ................................................................................................................. 13

6.8 Automation level ................................................................................................... 13

7 Requirements for battery swap system .......................................................................... 13

7.1 General ................................................................................................................. 13

7.2 Battery swap station (BSS) ................................................................................... 14

7.2.1 General ......................................................................................................... 14

7.2.2 Lane systems ................................................................................................ 15

7.2.3 Handling system ............................................................................................ 15

7.2.4 Requirements for storage system .................................................................. 16

7.2.5 Charging system ............................................................................................ 18

7.2.6 Supervisory and control system ..................................................................... 18

7.3 Supporting systems (optional) ............................................................................... 18

7.4 Removable battery systems .................................................................................. 18

7.4.1 General ......................................................................................................... 18

7.4.2 Interoperability requirements ......................................................................... 19

7.5 Power supply system (optional)............................................................................. 19

7.6 Interfaces .............................................................................................................. 19

7.7 Zones of accessibility ............................................................................................ 19

8 Communications ............................................................................................................ 20

9 Protection against electric shock ................................................................................... 20

10 Specific requirements for accessories ............................................................................ 20

11 Cable assembly requirements ........................................................................................ 20

12 DRI EV supply equipment constructional requirements and tests ................................... 20

12.3 IP degrees ............................................................................................................ 20

13 Overload and short-circuit protection ............................................................................. 20

14 Emergency switching or disconnect (optional) ............................................................... 20

15 Marking and instructions ................................................................................................ 21

15.1 Installation manual ................................................................................................ 21

Annex A (informative) Use cases ......................................................................................... 22

A.1 General ................................................................................................................. 22

A.2 Use case description ............................................................................................. 22

A.2.1 Convenience store device (attended) ............................................................. 22

A.2.2 Unattended locking compartment ................................................................... 23

A.2.3 Battery exchange box .................................................................................... 26

A.2.4 Automatic battery exchange box .................................................................... 28

A.2.5 Automatic vehicle storage system .................................................................. 29

Annex B (informative) Examples of BSS wirings for removable battery systems ................... 32

B.1 General ................................................................................................................. 32

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IEC PAS 62840-3:2021 © IEC 2021 – 3 –
B.2 Example of a BSS wiring providing independent VCU for each battery

system .................................................................................................................. 32

B.3 Example of a BSS wiring providing common VCU for all battery systems .............. 34

Annex C (informative) Examples of BSS for stackable removable battery systems ............... 35

C.1 General ................................................................................................................. 35

C.2 Connection of battery systems connected together ............................................... 35

Bibliography .......................................................................................................................... 38

Figure 1 – Composition of the battery swap system .............................................................. 14

Figure B.1 – Example of a removable battery system wiring (for information) ........................ 32

Figure B.2 – Example of a BSS wiring providing independent VCU for each battery

system .................................................................................................................................. 33

Figure B.3 – Example of a BSS wiring providing common VCU for all battery systems ......... 34

Figure C.1 – Example of a stackable removable battery system wiring .................................. 35

Figure C.2 – Example of a BSS for stackable removable battery systems ............................. 36

Figure C.3 – Connection of battery systems connected together ........................................... 37

Table 1 – Sub-systems mandatory for use-cases .................................................................. 14

Table 2 – Interoperability requirements ................................................................................. 19

Table A.1 – UC convenience store device (attended) ............................................................ 22

Table A.2 – UC unattended locking compartment DC ............................................................ 24

Table A.3 – UC unattended locking compartment AC ............................................................ 25

Table A.4 – UC battery exchange box ................................................................................... 27

Table A.5 – UC automatic battery exchange box ................................................................... 29

Table A.6 – UC automatic vehicle storage system ................................................................. 30

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– 4 – IEC PAS 62840-3:2021 © IEC 2021
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
ELECTRIC VEHICLE BATTERY SWAP SYSTEM –
Part 3: Particular safety and interoperability requirements for battery
swap systems operating with removable RESS/battery systems
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

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8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is

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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.

A PAS is an intermediate specification made available to the public and needing a lower level

of consensus than an International Standard to be approved by vote (simple majority).

IEC PAS 62840-3 has been processed by IEC technical committee 69: Electrical power/energy

transfer systems for electrically propelled road vehicles industrial trucks.
The text of this PAS is based on the This PAS was approved for
following document: publication by the P-members of the
committee concerned as indicated in
the following document
Draft PAS Report on voting
69/749/DPAS 69/772/RVDPAS

Following publication of this PAS, which is a pre-standard publication, the technical committee

or subcommittee concerned may transform it into an International Standard.
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IEC PAS 62840-3:2021 © IEC 2021 – 5 –

This PAS shall remain valid for an initial maximum period of 2 years starting from the publication

date. The validity may be extended for a single period up to a maximum of 2 years, at the end

of which it shall be published as another type of normative document, or shall be withdrawn.

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.
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– 6 – IEC PAS 62840-3:2021 © IEC 2021
INTRODUCTION

The IEC 62840 series is published in separate parts according to the following structure:

IEC TS 62840-1: Electric vehicle battery swap system – Part 1: General and guidance

IEC 62840-2: Electric vehicle battery swap system – Part 2: Safety requirements

IEC PAS 62840-3: Electric vehicle battery swap system – Part 3: Particular safety and

interoperability requirements for battery swap systems operating with removable RESS/battery

systems

This document derives from IEC 61851-3 (all parts) and was established by IEC TC 69 WG10

as a referencing document to IEC TS 61851-3-1.

NOTE In this document, EV supply equipment configuration type F according to IEC TS 61851-3-1 for removable

battery systems is named "battery swap station".

After moving of the document to IEC TC 69 WG13, IEC TC 69 decided to publish the document

as PAS based on IEC TS 61851-3-3 as an intermediate specification, which responds to

particular market needs according to 2.4.8 of ISO/IEC Directives, Part 1:2020, published prior

to the development of a full International Standard.

For this reason, this document is to be used in conjunction with IEC 61851-3 (all parts).

By the upcoming revision of IEC 62840 (all parts), this document will be fully integrated into the

IEC 62840 series.
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IEC PAS 62840-3:2021 © IEC 2021 – 7 –
ELECTRIC VEHICLE BATTERY SWAP SYSTEM –
Part 3: Particular safety and interoperability requirements for battery
swap systems operating with removable RESS/battery systems
1 Scope

This document applies to battery swap systems for removable RESS of electric road vehicle

when connected to the supply network, with a rated supply voltage up to 480 V AC or up to 400

V DC, for battery systems with a rated voltage up to 120 V DC.

NOTE 1 In the following countries, the acceptable nominal supply voltage is up to 600 V AC: CA, US.

This document applies to battery swap systems for removable RESS/EV where the removable

RESS/EV is stored for the purpose of transfer power between the battery swap station and

removable RESS/EV.

Requirements for bidirectional energy transfer DC to AC are under consideration and are not

part of this document.
This document applies to:

– battery swap systems supplied from on-site storage systems (for example buffer batteries

etc);
– manual, mechanically assisted and automatic systems;

– battery swap systems intended to supply removable battery systems having communication

allowing to identify the battery system characteristics;
– battery swap systems intended to be installed at an altitude of up to 2 000 m.
The aspects covered in this document include:
– requirements for power transfer between the battery systems;
– additional requirements for communication;
– the connection to supply network.
Additional requirements may apply to special locations.
This document does not apply to:
– safety requirements for mechanical equipment covered by ISO 10218 (all parts);

– locking compartments systems providing AC socket-outlets for the use of manufacturer

specific voltage converter units and manufacturer specific battery systems;
– safety aspects related to maintenance;

– electrical devices and components which are covered by their specific product standards;

– trolley buses, rail vehicles;
– any on-board equipment which is covered by ISO;

– EMC requirements for on-board equipment while connected to the supply, which are covered

by IEC 61851-21-1.

Requirements for battery swap systems using protective measures as covered by 410 of

IEC 60364-4-41:2005 other than double or reinforced insulation are under consideration.

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– 8 – IEC PAS 62840-3:2021 © IEC 2021
2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements of this document. 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 60529:1989, Degrees of protection provided by enclosures (IP Code)
IEC 60529:1989/AMD1:1999
IEC 60529:1989/AMD2:2013

IEC TS 61851-3-1:—, Electric vehicles conductive power supply system – Part 3-1: Particular

requirements for EV supply equipment where protection relies on double or reinforced insulation

– AC and DC conductive power supply systems

IEC TS 61851-3-2: —, Electric vehicles conductive power supply system – Part 3-2 Particular

requirements for EV supply equipment where protection relies on double or reinforced insulation

– Portable and mobile DRI EV supply equipment

IEC TS 61851-3-4: —, Electric vehicles conductive power supply system – Part 3-4 Particular

requirements for EV supply equipment where protection relies on double or reinforced insulation

– General definitions and requirements for CANopen communication

IEC TS 61851-3-5: —, Electric vehicles conductive power supply system – Part 3-5 Particular

requirements for EV supply equipment where protection relies on double or reinforced insulation

– Pre-defined communication parameters and general application objects

IEC TS 61851-3-6: —, Electric vehicles conductive power supply system – Part 3-6: Particular

requirements for EV supply equipment where protection relies on double or reinforced insulation

– Voltage converter unit communication

IEC TS 61851-3-7: —, Electric vehicles conductive power supply system – Part 3-7: Particular

requirements for EV supply equipment where protection relies on double or reinforced insulation

– Battery system communication

IEC TS 62196-4:—, Plugs, socket-outlets, vehicle connectors and vehicles inlet – Conductive

charging of electric vehicles – Part 4: Dimensional compatibility and interchangeability

requirements for DC pin and contact-tube accessories for class II or class III applications

IEC TS 62840-1:2016, Electric vehicle battery swap system – Part 1: General and guidance

IEC 62840-2:2016, Electric vehicle battery swap system – Part 2: Safety requirements

Under preparation. Stage at the time of publication: IEC ADTS 61851-3-1:2021.
Under preparation. Stage at the time of publication: IEC ADTS 61851-3-2:2021.
Under preparation. Stage at the time of publication: IEC RPUB 61851-3-4:2021.
Under preparation. Stage at the time of publication: IEC RPUB 61851-3-5:2021.
Under preparation. Stage at the time of publication: IEC RPUB 61851-3-6:2021.
Under preparation. Stage at the time of publication: IEC RPUB 61851-3-7:2021.
Under preparation. Stage at the time of publication: IEC BPUB TS 62196-4:2021.
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IEC PAS 62840-3:2021 © IEC 2021 – 9 –

IEC TS 63066:2017, Low-voltage docking connectors for removable energy storage units

ISO 10218-1:2011, Robots and robotic devices – Safety requirements for industrial robots –

Part 1: Robots

ISO 10218-2:2011, Robots and robotic devices – Safety requirements for industrial robots –

Part 2: Robot systems and integration
ISO 19353:2019, Safety of machinery – Fire prevention and fire protection
EN 14470 (all parts), Fire safety storage cabinets

EN 50604-1:2016, Secondary lithium batteries for light EV (electric vehicle) applications – Part

1: General safety requirements and test methods
EN 50604-1:2016/AMD1:2021
3 Terms and definitions

ISO and IEC maintain terminological databases for use in standardization at the following

addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
3.1
battery swap system
battery swap station and supporting systems
[SOURCE: IEC TS 62840-1:2016, 3.2]
3.2
battery swap station
BSS
facility that provides a removable battery swap service for EVs and client

Note 1 to entry: In the context of this document, BSS is representing the DRI EV supply equipment type F according

to IEC TS 61851-3-1.
[SOURCE: IEC TS 62840-1:2016, 3.4 modified – Addition of Note 1]
3.3
supporting system
system which serves the battery swap station
[SOURCE: IEC TS 62840-1:2016, 3.3]
3.4
battery pack

energy storage device that includes cells or cell assemblies normally connected with cell

electronics, power supply circuits and overcurrent shut-off device, including electrical

interconnections, interfaces for external systems
Note 1 to entry: See Clause A.2 of ISO 12405-4:2018 for further explanations.

Note 2 to entry: Examples of external systems are cooling, voltage class B, auxiliary voltage class A and

communication
[SOURCE: ISO 12405-4:2018, 3.2]
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– 10 – IEC PAS 62840-3:2021 © IEC 2021
3.5
battery swap equipment
swap equipment
equipment used for mounting/unmounting removable battery system to/from EVs

Note 1 to entry: The battery transferring function may be integrated in the battery swap equipment

[SOURCE: IEC TS 62840-1:2016, 3.13, modified – SBS is replaced by removable battery

system.]
3.6
handling system

equipment that provides the function of moving, positioning or otherwise manipulating

removable battery systems
Note 1 to entry: Handling system could be a part of BSS or external to the BSS.
3.7
battery control unit
BCU

electronic device that controls, manages, detects or calculates electric and thermal functions of

the battery system and that provides communication between the battery system and other

vehicle controllers
Note 1 to entry: See also Annex A for further explanation.
[SOURCE: ISO 12405-4:2018, 3.1]
3.8
battery management system
BMS

local energy management system (EMS unit) for the battery system, protecting the battery

system from damage, monitoring and increasing the lifetime, and maintaining the functional

state

Note 1 to entry: BMS and BCU (according to ISO 12405 all parts) do not have the same functions.

[SOURCE: IEC TS 61851-3-4, 3.7]
3.9
removable battery system
removable RESS
RBS

battery system/RESS that can be moved/removed from an EV by hand (portable RESS) or with

the assistance of an installation/device (mobile RESS)
3.10
RESS coupler
means enabling the connection of RESS to an EV or a DRI EV supply equipment
3.11
double or reinforced insulated EV supply equipment
DRI EV supply equipment

EV supply equipment in which protection against electric shock relies on double insulation or

reinforced insulation, there being no provision for protective earthing or reliance upon

installation conditions
[SOURCE: IEC TS 61851-3-1:—, 3.1.1]
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IEC PAS 62840-3:2021 © IEC 2021 – 11 –
3.12
EV supply system

complete system including the DRI EV supply equipment and the EV/RESS functions that are

required to transfer power between the fixed installation or supply network and the EV/RESS

[SOURCE: IEC TS 61851-3-1:—, 3.1.2]
3.13
charging

all functions necessary to condition voltage and/or current provided by the AC or DC supply

network to assure the supply of electric energy to the RESS
[SOURCE: IEC 61851-1:2017, 3.1.8]
3.14
voltage converter

set of equipment to convert one type of electric current to another type different in nature,

voltage and/or frequency

[SOURCE: IEC 60050-811:2017, 811-19-01, modified – The word "voltage" has been added to

the term, and the words "static or rotating" has been deleted from the definition.]

3.15
voltage converter unit
VCU
voltage converter with local EMS and communication interface
[SOURCE: IEC TS 61851-3-1:—, 3.1.8]
3.16
DC power circuit
circuit for DC conductive power transfer
[SOURCE: IEC TS 61851-3-1:—, 3.1.11]
3.17
gateway

functional unit that connects two networks with different network architectures and protocols

[SOURCE: IEC 60050-732:1998, 732-01-17, modified – The words "computer networks" has

been replaced by "networks" in the definition, and Note 1 and 2 have been deleted.]

3.18
energy management system
EMS

system consisting of active and passive devices for controlling the power transfer

[SOURCE: IEC TS 61851-3-1:—, 3.3.3]
3.19
active device
device connected to DC power circuit, AUX circuit and CAN circuit
[SOURCE: IEC TS 61851-3-1:—, 3.3.4]
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– 12 – IEC PAS 62840-3:2021 © IEC 2021
3.20
passive device
device connected to AUX circuit and CAN circuit
[SOURCE: IEC TS 61851-3-1:—, 3.3.5]
3.21
energy management system controller
EMSC

device or virtual device that manages the communication as well as the energy exchange

[SOURCE: IEC TS 61851-3-4:—, 3.9]
4 Abbreviated terms
BCU battery control unit
BMS battery management system
BSS battery swap station
EMSC energy management system controller
EMS energy management system
HMI human machine interface
SOC state of charge
SOH state of health
VCU voltage converter unit
5 General requirements

The battery swap system for removable battery systems described in this document allows

simul
...