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.