IEC 62840-2:2025
(Main)Electric vehicle battery swap system - Part 2: Safety requirements
Electric vehicle battery swap system - Part 2: Safety requirements
IEC 62840-2:2025 provides the safety requirements for a battery swap system, for the purposes of swapping swappable battery system (SBS)/handheld-swappable battery system (HBS) of electric vehicles. The battery swap system is intended to be connected to the supply network. The power supply is up to 1 000 V AC or up to 1 500 V DC in accordance with IEC 60038. This document also applies to battery swap systems supplied from on-site storage systems (e.g. buffer batteries).
Aspects covered in this document:
• safety requirements of the battery swap system and its systems;
• security requirements for communication;
• electromagnetic compatibility (EMC);
• marking and instructions;
• protection against electric shock and other hazards.
This document is applicable to battery swap systems for EV equipped with one or more SBS/HBS.
This document is not applicable to
• aspects related to maintenance and service of the battery swap station (BSS),
• trolley buses, rail vehicles and vehicles designed primarily for use off-road, and
• maintenance and service of EVs.
Requirements for bidirectional energy transfer are under consideration
This second edition cancels and replaces the first edition published in 2016. This edition constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous edition:
a) expands the scope to encompass both swappable battery systems (SBS) and handheld swappable battery systems (HBS);
b) introduces stricter interoperability requirements through detailed system interface specifications and defined state transition protocols;
c) enhances data security by defining safety message transmission protocols and integrating telecom network requirements;
d) increases electrical safety protection levels for battery swap stations (BSS) with specified capacitor discharge time limits to mitigate electric shock risks;
e) introduces enhanced mechanical safety requirements for automated battery handling systems, with technical alignment to ISO 10218-1 and ISO 10218-2;
f) strengthens overload and short-circuit protection for BSS through standardized testing methods and overcurrent protection specifications;
g) defines upgraded electromagnetic compatibility (EMC) standards to ensure system resilience against external interference, supplemented with EMC-related functional safety measures.
This document is to be read in conjunction with IEC 62840-1:2025.
Système d'échange de batterie de véhicule électrique - Partie 2: Exigences de sécurité
L'IEC 62840-2:2025 spécifie les exigences de sécurité relatives à un système d’échange de batterie, afin de remplacer le système de batterie échangeable (SBS)/le système de batterie échangeable portative (HBS) des véhicules électriques. Le système d’échange de batterie est destiné à être connecté au réseau électrique. L’alimentation atteint 1 000 V en courant alternatif ou 1 500 V en courant continu, conformément à l’IEC 60038. Le présent document s’applique également aux systèmes d’échange de batterie alimentés par des systèmes de stockage sur site (par exemple, des batteries tampons).
Le présent document traite des aspects suivants:
• les exigences de sécurité du système d’échange de batterie et de ses sous-systèmes;
• les exigences de sûreté de la communication;
• la compatibilité électromagnétique (CEM);
• le marquage et les indications;
• la protection contre les chocs électriques et autres phénomènes dangereux.
Le présent document s’applique aux systèmes d’échange de batterie pour les VE équipés d’un ou de plusieurs SBS/HBS.
Le présent document ne concerne pas:
• les aspects liés à la maintenance et à l’entretien de la station d’échange de batterie (BSS);
• les trolleys bus, véhicules ferroviaires et véhicules destinés principalement à une utilisation tout terrain; et
• la maintenance et l’entretien des VE.
Les exigences relatives au transfert d’énergie bidirectionnel sont à l’étude.
Cette deuxième édition annule et remplace la première édition parue en 2016. Cette édition constitue une révision technique.
Cette édition inclut les modifications techniques majeures suivantes par rapport à l’édition précédente:
a) extension du domaine d’application pour englober à la fois les systèmes de batteries échangeables (SBS, Swappable Battery System) et les systèmes de batteries échangeables portatives (HBS, Handheld swappable Battery System);
b) introduction d’exigences d’interopérabilité plus strictes par le biais de spécifications d’interface système détaillées et de protocoles définis pour le passage entre les différents états;
c) renforcement de la sûreté des données en définissant des protocoles de transmission des messages de sécurité et en intégrant les exigences des réseaux de télécommunications;
d) augmentation des niveaux de protection de sécurité électrique pour les stations d’échange de batteries (BSS, Battery Swap Station), par le biais de limites spécifiées de temps de décharge des condensateurs, afin d’atténuer les risques de choc électrique;
e) introduction d’exigences de sécurité mécanique renforcées pour les systèmes automatisés de manutention des batteries, avec un alignement technique sur l’ISO 10218-1 et l’ISO 10218-2;
f) renforcement de la protection des BSS contre les surcharges et les courts-circuits, au moyen de méthodes d’essai normalisées et de spécifications de protection contre les surintensités;
g) définition de normes de compatibilité électromagnétique (CEM) améliorées pour assurer la résilience du système aux perturbations externes, complétées par des mesures de sécurité fonctionnelle liées à la CEM.
General Information
Relations
Standards Content (Sample)
IEC 62840-2 ®
Edition 2.0 2025-07
INTERNATIONAL
STANDARD
COMMENTED VERSION
Electric vehicle battery swap system -
Part 2: Safety requirements
ICS 43.120 ISBN 978-2-8327-0567-4
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CONTENTS
FOREWORD . 4
INTRODUCTION . 7
1 Scope . 8
2 Normative references . 8
3 Terms and definitions . 11
4 Abbreviated terms . 13
5 General requirements . 13
6 Classification . 14
7 Safety requirements of systems . 14
7.1 General . 14
7.2 Lane system . 14
7.2.1 Vehicle lane . 14
7.2.2 Measures in case of emergency . 15
7.3 Battery handling system . 15
7.3.1 Interlock protection guarding . 15
7.3.2 Interlock with the lane . 15
7.3.3 Battery handling process . 15
7.3.4 Measures in case of emergency . 16
7.4 Storage system . 17
7.4.1 Battery storage . 17
7.4.2 Measures in case of emergency . 18
7.5 Charging system . 18
7.5.1 SBS/HBS charger . 18
7.5.2 Charger connection . 19
7.5.3 Charging rack . 19
7.5.4 Communication and monitoring . 19
7.6 Swappable battery system SBS/HBS . 20
7.6.1 General . 20
7.6.2 Interoperability requirements . 20
7.7 Supervisory and control system . 20
7.8 Supporting systems . 21
7.8.1 Battery maintenance system . 21
7.8.2 SBS/HBS logistic system . 21
7.9 Power supply system . 22
7.10 Interfaces. 22
8 Communication . 22
8.1 Data security . 22
8.2 Transmission of safety related messages . 22
8.3 Telecommunication network . 22
9 Protection against electric shock . 22
9.1 General requirements . 22
9.2 Protection against direct contact Provisions for basic protection . 23
9.2.1 IP degrees for the enclosures shock prevention . 23
9.2.2 IP degrees for coupler . 24
7.2.3 Bidirectional energy transfer .
9.2.3 Stored energy – discharge of capacitors . 24
9.3 Fault protection . 24
9.4 Protective conductor . 24
9.5 Supplementary measures. 25
9.5.1 Additional protection . 25
9.5.2 Manual/automatic reset . 25
9.5.3 Protection of persons against electric shock . 25
7.7 Telecommunication network .
10 Specific requirements for accessories. 26
11 Cable assembly requirements . 26
12 Equipment BSS constructional requirements . 26
12.1 General . 26
12.2 Characteristics of mechanical switching devices . 26
12.2.1 Switch and switch-disconnector . 26
12.2.2 Contactor . 26
12.2.3 Circuit-breaker . 27
12.2.4 Relays . 27
12.2.5 Metering . 27
12.2.6 Switch-on peak current/Inrush current . 27
12.3 Clearances and creepage distances. 27
12.4 IP degrees for the penetration . 27
12.5 Insulation resistance . 28
12.6 Touch current . 28
12.7 Dielectric withstand voltage . 29
12.7.1 AC withstand voltage . 29
12.7.2 Impulse dielectric withstand (1,2 µs/50 µs) . 29
12.8 Temperature rise . 29
12.9 Damp heat functional test . 29
12.10 Minimum temperature functional test . 29
12.11 Strength of materials and parts . 29
12.11.1 General . 29
12.11.2 Mechanical impact . 29
12.11.3 Environmental conditions . 30
12.11.4 Properties of insulating materials . 30
13 Overload and short-circuit protection . 31
14 Electromagnetic compatibility (EMC) . 31
14.1 General . 31
14.2 EMC of the BSS . 32
14.3 Functional safety related to EMC . 32
15 Emergency switching or disconnect (optional) . 32
16 Marking and instructions . 32
16.1 Installation manual of battery swap station . 32
16.2 User manual for battery swap station . 33
16.3 Marking of battery swap station. 33
16.3.1 General . 33
16.3.2 Marking of equipment . 33
16.4 Legibility . 33
16.5 Signals and warning devices . 34
Annex A (informative) Interface of system A for type B BSS . 35
A.1 General . 35
A.2 Interface circuit . 35
A.2.1 Interface circuit diagram . 35
A.2.2 Control pilot circuit . 36
A.3 State transition of charging control process . 37
Annex B (informative) Interface of system B for type B BSS . 39
B.1 General . 39
B.2 Interface circuit . 39
B.3 State transition of charging control process . 40
Bibliography . 42
List of comments. 44
Figure A.1 – Example of Interface circuit for charging control of system A station . 36
Figure A.2 – State transition diagram of charging process for system A station . 38
Figure B.1 – Example of interface circuit for charging control of system B station . 40
Figure B.2 – State transition diagram of charging process for system B station . 41
Table 1 – Interoperability requirements . 20
Table 2 – Touch current limits . 28
Table A.1 – Voltage of control pilot circuit . 37
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
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6) All users should ensure that they have the latest edition of this publication.
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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) IEC draws attention to the possibility that the implementation of this document may involve the use of (a)
patent(s). IEC takes no position concerning the evidence, validity or applicability of any claimed patent rights in
respect thereof. As of the date of publication of this document, IEC had not received notice of (a) patent(s), which
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the latest information, which may be obtained from the patent database available at https://patents.iec.ch. IEC
shall not be held responsible for identifying any or all such patent rights.
This commented version (CMV) of the official standard IEC 62840-2:2025 edition 2.0 allows the
user to identify the changes made to the previous IEC 62840-2:2016 edition 1.0. Furthermore,
comments from IEC TC 69 experts are provided to explain the reasons of the most relevant
changes, or to clarify any part of the content.
A vertical bar appears in the margin wherever a change has been made. Additions are in green
text, deletions are in strikethrough red text. Experts' comments are identified by a blue-
background number. Mouse over a number to display a pop-up note with the comment.
This publication contains the CMV and the official standard. The full list of comments is available
at the end of the CMV.
IEC 62840-2 has been prepared by IEC technical committee 69: Electrical power/energy
transfer systems for electrically propelled road vehicles and industrial trucks. It is an
International Standard.
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.
The text of this International Standard is based on the following documents:
Draft Report on voting
69/1046/FDIS 69/1062/RVD
Full information on the voting for its approval can be found in the report on voting indicated in
the above table.
The language used for the development of this International Standard is English.
This document was drafted in accordance with ISO/IEC Directives, Part 2, and developed in
accordance with ISO/IEC Directives, Part 1 and ISO/IEC Directives, IEC Supplement, available
at www.iec.ch/members_experts/refdocs. The main document types developed by IEC are
described in greater detail at www.iec.ch/publications.
This document is to be read in conjunction with IEC 62840-1:2025.
In this document, the following print types are used:
– test specifications: in italic type;
The following differing practices of a less permanent nature exist in the countries indicated
below:
– 7.5.4: the battery passport defines the necessary data to be transmitted (EU).
– 7.6.1: RCDs of type AC may be used (JP).
– 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 (US).
– 9.4: the size and rating of the protective conductor is determined by national codes and
regulations (CA, US, JP).
– 9.5.1: RCDs of type AC may be used (JP).
– 9.5.1: 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 (US).
– 12.2.1: national standards or regulations provide the different requirements (JP).
– 12.2.2: national standards or regulations provide the different requirements (JP).
– Clause 13: the methods of protection against overcurrent and overvoltage are in accordance
with national codes (US, JP, CA).
– Clause 13: the branch circuit overcurrent protection is based upon 125 % of the equipment
rating (US, CA).
– Clause 13: EV charging is considered a continuous load and is limited to 80 % of the branch
circuit fuse or circuit breaker rating by national rules (US, CA).
– Clause 13: the equipment earthing path complies with the test requirement in national
standard (JP).
– 16.5: three-part cautionary statements are required (US).
– 16.5: the use of specific language(s) is covered by legal requirements (CN).
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 committee has decided that the contents of this document will remain unchanged until the
stability date indicated on the IEC website under webstore.iec.ch in the data related to the
specific document. At this date, the document will be
• reconfirmed,
• withdrawn, or
• revised.
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) or handheld-
swappable battery systems (HBS). 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. 1 The battery swap system
aims to provide energy to electric road vehicles by quickly replacing their swappable battery
system or handheld-swappable battery system. This may help alleviate range anxiety and make
longer distance travel more convenient.
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 is
minimized.
Battery swap stations mainly include one or more of the following functions:
• swap of EV swappable battery system (SBS) SBS or HBS;
• storage of EV SBS or HBS;
• charging and cooling of EV SBS or HBS;
• testing, maintenance and safety management of EV SBS or HBS.
This document serves as a generic approach for safety during the lifecycle of battery swap
systems and stations for electric vehicles.
This document contains the general safety requirements for battery swap system of SBS/HBS.
The specific safety requirements for dedicated system are described in other parts of the
IEC 62840 series.
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)/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/or its subsystems;
• security requirements for communication;
• electromagnetic compatibility (EMC);
• signs 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.
NOTE Battery swap systems for light EVs according to the IEC 61851-3 series are under consideration.
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.
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 60068-2-1, Environmental testing – Part 2-1: Tests – Test A: Cold
IEC 60068-2-78, Environmental testing – Part 2-78: Tests – Test Cab: Damp heat, steady state
IEC 60112, Method for the determination of the proof and the comparative tracking indices of
solid insulating materials
IEC 60127 (all parts), Miniature fuses
IEC 60204-1, Safety of machinery – Electrical equipment of machines – General requirements
___________
Under consideration.
IEC 60269 (all parts), Low-voltage fuses
IEC 60364 (all parts), Low-voltage electrical installations
IEC 60364-4-41:2005, Low-voltage electrical installations – Part 4-41: Protection for safety –
Protection against electric shock
IEC 60364-4-41:2005/AMD1:2017
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 60664-1:20072020, 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 safety requirements for residual current operated protective devices
IEC 60898 (all parts), Electrical accessories – Circuit-breakers for overcurrent protection for
household and similar installations
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 60947-6-2, Low-voltage switchgear and controlgear – Part 6-2: Multiple function equipment
– Control and protective switching devices (or equipment) (CPS)
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 60990, Methods of measurement of touch current and protective conductor current
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 locations
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 61439-1:20112020, Low-voltage switchgear and controlgear assemblies – Part 1: General
rules
IEC 61439-7:2022, Low-voltage switchgear and controlgear assemblies – Part 7: Assemblies
for specific applications such as marinas, camping sites, market squares, electric vehicle
charging stations
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 61851-1:2017, Electric vehicle conductive charging system – Part 1: General requirements
IEC 61851-21-2, Electric vehicle conductive charging system – Part 21-2: Electric vehicle
requirements for conductive connection to an AC/DC supply – EMC requirements for off board
electric vehicle charging systems
IEC 61851-23:20142023, Electric vehicle conductive charging system – Part 23: DC electric
vehicle charging station supply equipment
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 62368-1:2023, Audio/video, information and communication technology equipment – Part 1:
Safety requirements
IEC 62423, Type F and type B residual current operated circuit-breakers with and without
integral overcurrent protection for household and similar uses
IEC 62477-1:2022, Safety requirements for power electronic converter systems and equipment
– Part 1: General
IEC 62840-1:20162025, Electric vehicle battery swap system – Part 1: General and guidance
IEC 63066: — , Low-voltage docking connectors for removable energy storage units
ISO 2972, Numerical control of machines – Symbols
ISO 7000, Graphical symbols for use on equipment – Registered symbols
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 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
ISO 19353:2019, Safety of machinery – Fire prevention and fire protection
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 62840-1 and the
following apply.
ISO and IEC maintain terminology databases for use in standardization at the following
addresses:
• IEC Electropedia: available at https://www.electropedia.org/
• ISO Online browsing platform: available at https://www.iso.org/obp
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
, 195-06-03, modified – The words "human beings or
[SOURCE: IEC 60050-195:19982021
livestock" have been replaced with "persons or animals".] 2
___________
Under preparation. Stage at the time of publication: IEC CCDV 63066:2024
3.4
indirect contact
electric contact of persons or animals with exposed-conductive-parts which have become live
under fault conditions
[SOURCE: IEC 60050-195:19982021, 195-06-04, modified – The words "human beings or
livestock" have been replaced with "persons or animals".] 2
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 60050-195:19982021, 195-02-19, modified – The note to entry has been
deleted. The domain has been deleted. The words "conductor or" have been added in the
definition, "mid-point conductor" has been removed.] 2
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). See also ISO/IEC Guide 51:19992014, 3.2.
[SOURCE: IEC 60050-903:19982013, 903-01-07, modified – The reference to ISO/IEC Guide
51 has been updated in the note to entry.] 2
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 IEC 60050-171:2019,171-05-53] 3
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. The abbreviated term "AC" has been added. The note to entry has been deleted.]
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. The abbreviated term "DC" has been added. The note to entry has been deleted.]
3.10
residual current device
RCD
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 60050-442:19982019, 442-05-02, modified – The note to entry has been
deleted. The words "or association of devices" have been deleted.]
3.11
basic protection 4
protection against electric shock under fault-free conditions
[SOURCE: IEC 60050-195:2021, 195-06-01, modified – The word "normal" has been replaced
with "fault-free".]
3.12
fault protection
protection against electric shock under single fault conditions
[SOURCE: IEC 60050-195:2021, 195-06-02]
4 Abbreviated terms
IEC 62840-1:2025, Clause 4, applies.
5 General requirements 5
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 document, 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.
The battery swap system shall be designed to consider the environmental impact (dust, water,
ice, etc.) to the equipment or human safety. In general, this principle is achieved by fulfilling
the relevant requirements specified by this document and IEC 62840-1, together with
IEC 61851-21-2 .
Compliance is checked by carrying out the relevant tests.
For robots and robotic devices and their integration into the BSS, a hazard identification and
risk assessment shall be provided according to ISO 10218-1:2011, Clause 4, or
ISO 10218-2:2011, Clause 4, and under consideration of ISO 10218-1:2011, Annex A and
Annex F, or ISO 10218-2:2011, Annex A and Annex G, depending on the application.
NOTE For BSS with more than one robot systems implemented in the same application, ISO 10218-2 is applicable.
___________
Under consideration.
Additional attention regarding hazards of fire shall be given by the risk assessment according
to ISO 19353:2019.
Unless otherwise stated, The hazards of fire 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 document.
The electrical interface and communication interface characteristics of a specific battery swap
system will be specified in another part of the IEC 62840 series shall be defined in terms of
safety and compatibility.
For additional informative details regarding type B BSS, refer to Annex A and Annex B.
6 Classification
IEC 62840-1:2025, Clause 6, applies.
7 Safety requirements of systems
7.1 General
For type A BSS, 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
document.
For type B BSS, the battery swap system for electrical vehicles shall be in accordance with
IEC 62477-1. Specific requirements are the subject of this document. 6
7.2 Lane system
7.2.1 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 safety and function relevant 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. To protect the driver
and passengers, at least one of the following requirements shall be applied.
a) If the driver or passengers intend to get off the vehicle, a warning message or symbols shall
be displayed or a protection obstacle to prevent opening the vehicle doors shall be provided.
b) If the driver or passengers are getting off the vehicle, an emergency shutdown of the
swapping process shall be performed.
For the battery swap system which does not allow drivers and passengers to stay on-board
during the battery swap process, the safety measures shall be provided to pause/stop the
process when the drivers and passengers are still inside the vehicle. 7
7.2.2 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.
During the movement of the vehicle within the lane system, an emergency stop measure shall
be provided to stop the movement 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 another emergency. National or local regulations can apply. 8
All Marking, routing and geometry of escape routes and exits should can be done according
subject to local regulations.
To ensure the fire protection purpose, one of the following measures, but not limited to, shall
be adopted in the system design of BSS:
– detection of the thermal changing (thermal detection, smoke d
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