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.
