WG 13 - TC 69/WG 13

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.

IEC 62840-1:2025 gives the general overview for battery swap systems, for the purposes of swapping batteries of electric road vehicles when the vehicle powertrain is turned off and when the battery swap system is connected to the supply network at standard supply voltages according to IEC 60038 with a rated voltage up to 1 000 V AC and up to 1 500 V DC.
This document is applicable for battery swap systems for EV equipped with one or more
– swappable battery systems (SBS), or
– handheld-swappable battery systems (HBS).
This document provides guidance for interoperability.
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 SBS/HBS having communication allowing to identify the battery system characteristics, and
• battery swap systems intended to be installed at an altitude of up to 2 000 m.
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,
• maintenance and service of EVs,
• safety requirements for mechanical equipment covered by the ISO 10218 series,
• locking compartments systems providing AC socket-outlets for the use of manufacturer specific voltage converter units and manufacturer specific battery systems,
• electrical devices and components, which are covered by their specific product standards,
• any fix-installed equipment of EV, which is covered by ISO, and
• EMC requirements for on-board equipment of EV while connected to the BSS.
This first edition cancels and replaces the first edition of IEC TS 61280-1 published in 2016.
This edition includes the following significant technical changes with respect to IEC TS 61280-1:2016:
a) expanded scope to include handheld-swappable battery systems (HBS) and guidance on interoperability;
b) added definitions for "handheld-swappable battery system" (HBS) and expanded related terms such as "SBS/HBS coupler," "SBS/HBS charger," etc;
c) added classifications based on supply network characteristics, connection method, access and type of BSS;
d) added support for HBS, detailing the different compositions and workflows for type A (SBS) and type B (HBS) battery swap stations;
e) added requirements for functional interoperability, interface interoperability, data interoperability, operational interoperability, compatibility with legacy systems, and scalability;
f) added requirements for communication, protection against electric shock, specific requirements for accessories), cable assembly requirements, BSS constructional requirements, overload and short circuit protection, EMC, emergency switching or disconnect, marking and instructions;
g) expanded annex content, adding solutions for manual swapping stations for motorcycles with HBS and updating use cases.

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.

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.