BS EN IEC 62840-2:2025: Electric Vehicle Battery Swap System Safety Requirements

The BS EN IEC 62840-2:2025 is a comprehensive standard that outlines the safety requirements for electric vehicle battery swap systems. As the world moves towards sustainable energy solutions, electric vehicles (EVs) are at the forefront of this transformation. This standard ensures that the battery swap systems, which are crucial for the efficient operation of EVs, adhere to the highest safety protocols.

Key Features of the Standard

• Standard Number: BS EN IEC 62840-2:2025
• Pages: 52
• Release Date: October 14, 2025
• ISBN: 978 0 539 12806 2
• Status: Standard

Why This Standard is Essential

As electric vehicles become more prevalent, the need for efficient and safe battery swap systems becomes increasingly important. The BS EN IEC 62840-2:2025 standard provides a framework that manufacturers and operators can follow to ensure that their systems are not only efficient but also safe for users and the environment. This standard is crucial for several reasons:

1. Ensuring User Safety

Safety is paramount when it comes to handling high-voltage battery systems. This standard outlines the necessary safety measures that need to be in place to protect users from potential hazards associated with battery swapping. It covers aspects such as electrical safety, mechanical safety, and thermal management to prevent accidents and injuries.

2. Promoting Environmental Sustainability

Electric vehicles are a key component in reducing carbon emissions and promoting environmental sustainability. The BS EN IEC 62840-2:2025 standard ensures that battery swap systems are designed and operated in a way that minimizes environmental impact. This includes guidelines on the disposal and recycling of batteries, as well as measures to prevent environmental contamination.

3. Enhancing System Efficiency

Efficiency is critical in the operation of battery swap systems. This standard provides guidelines on optimizing the design and operation of these systems to ensure quick and efficient battery swaps. This not only improves the user experience but also enhances the overall performance of electric vehicles.

4. Facilitating Industry Compliance

Compliance with international standards is essential for manufacturers and operators in the electric vehicle industry. The BS EN IEC 62840-2:2025 standard provides a clear set of requirements that must be met, facilitating compliance and ensuring that products meet global safety and quality benchmarks.

Who Should Use This Standard?

This standard is designed for a wide range of stakeholders in the electric vehicle industry, including:

• Manufacturers: Companies involved in the design and production of battery swap systems can use this standard to ensure their products meet safety and efficiency requirements.
• Operators: Businesses that operate battery swap stations can implement the guidelines to enhance safety and service quality.
• Regulatory Bodies: Government and regulatory agencies can use this standard as a benchmark for evaluating the safety and compliance of battery swap systems.
• Researchers and Developers: Individuals and organizations involved in the research and development of electric vehicle technologies can use this standard to guide their innovations.

Conclusion

The BS EN IEC 62840-2:2025 standard is an essential document for anyone involved in the electric vehicle industry. By providing a comprehensive set of safety requirements, it ensures that battery swap systems are safe, efficient, and environmentally friendly. As the demand for electric vehicles continues to grow, adherence to this standard will be crucial in advancing the industry and promoting sustainable transportation solutions.

BS EN IEC 62840-2:2025

This standard BS EN IEC 62840-2:2025 Electric vehicle battery swap system is classified in these ICS categories:

• 43.120 Electric road vehicles

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.